TC5100

CONTENTS
CHAPTER 1: MAINTENANCE
1. Preface .............................................................................................................................................. 1-2 CAUTION ........................................................................................................................................... 1-3 WARNING .......................................................................................................................................... 1-4 2. 3. 4. Work Precautions ............................................................................................................................. 1-5 Installation ........................................................................................................................................ 1-7 Exterior Cover Removal .................................................................................................................. 1-11
CHAPTER 2: MACHINE SUMMARY

1. 2. 3. 4. Features ............................................................................................................................................ 2-2 Specifications ................................................................................................................................... 2-3 Product Configuration ....................................................................................................................... 2-4 Cross-Sectional View ....................................................................................................................... 2-5
CHAPTER 3: MAIN-UNIT DRIVE AREA

Mechanism ................................................................................................................................................... 3-2 1. 2. Drive-Area Rotating Mechanism ...................................................................................................... 3-2 Main-Motor Safety Mechanism ......................................................................................................... 3-3
Disassembly ................................................................................................................................................. 3-4 1. 2. 3. Removal of the Main Belt .................................................................................................................. 3-4 Removal of the Main Motor ............................................................................................................... 3-5 Removal of the Main-Motor Safety Switch ........................................................................................ 3-6
CHAPTER 4: PAPER-FEED AREA

Mechanisms ................................................................................................................................................. 4-2 1. 2. 3. 4. Paper-Tray Mechanism .................................................................................................................... 4-2 Paper-Tray Elevating Mechanism .................................................................................................... 4-3 Paper-Feeding Mechanism .............................................................................................................. 4-5 Paper-Feed Stripping Mechanism ................................................................................................... 4-6
Disassembly ................................................................................................................................................. 4-7 1. 2. 3. 4. 5. 6. 7. 8. Removal of feed rollers .................................................................................................................... 4-7 Removal of the stripper plate ........................................................................................................... 4-7 Removal of paper-detection sensors .............................................................................................. 4-8 Removal of Paper-Feed Detection Sensors .................................................................................... 4-9 Removal of Paper-Feed Clutches ................................................................................................. 4-10 Removal of the Elevator Motor ........................................................................................................ 4-11 Removal of Paper Trays ................................................................................................................ 4-12 Removal of Guide Plates .............................................................................................................. 4-14
1 TC (Version 1.0)
9.
Removal of the Transport Roller ................................................................................................... 4-15
10. Removal of the Drive Belt .............................................................................................................. 4-16
CHAPTER 5: VERTICAL-TRANSPORT AREA

Mechanisms ................................................................................................................................................. 5-2 1. 2. Vertical-Transport Mechanism ......................................................................................................... 5-2 Main-Motor Safety Mechanism ......................................................................................................... 5-2
Disassembly ................................................................................................................................................. 5-3 1. Removal of the Transport Belt .......................................................................................................... 5-3
CHAPTER 6: PAPER-EJECTION AREA

Mechanism ................................................................................................................................................... 6-2 Collated-Sheet Ejection Mechanism ...................................................................................................... 6-2 Disassembly ................................................................................................................................................. 6-4 1. 2. 3. 4. Removal of Paper-Ejection Roller (upper) ....................................................................................... 6-4 Removal of Paper-Ejection Roller (lower) ....................................................................................... 6-6 Removal of Paper-Ejection Sensor (upper) ..................................................................................... 6-7 Removal of Paper-Ejection Sensor (lower) ..................................................................................... 6-8
CHAPTER 7: STACKER AREA

Mechanism ................................................................................................................................................... 7-2 1. 2. 3. 4. 5. Collated-Sheet Stacking Mechanism ............................................................................................... 7-2 Paper-Ejection-Wing Mechanism .................................................................................................... 7-4 Paper-Ejection-Wing Initializing Mechanism ................................................................................... 7-8 Paper-Ejection-Wing Initializing Mechanism (Left-hand-alignment) ............................................... 7-9 Collated-Sheet Full-Detection Mechanism ................................................................................... 7-10
Disassembly ............................................................................................................................................... 7-11 1. 2. 3. 4. 5. 6. Removal of the Stacker Unit ........................................................................................................... 7-11 Removal of the Stacker Motor ........................................................................................................ 7-12 Removal of the Stacker Sensor ..................................................................................................... 7-13 Removal of the Stacker Home Sensor ......................................................................................... 7-13 Removal of the Full-Detection Sensor (Send) .............................................................................. 7-14 Removal of the Full-Detection Sensor (Rcv.) ................................................................................ 7-15
CHAPTER 8: VARIOUS SETTINGS

1. 2. 3. Initialization Settings ......................................................................................................................... 8-2 Maintenance Call .............................................................................................................................. 8-3 Double-Feed-Detection Cancellation Function ............................................................................... 8-4
CHAPTER 9: PANEL DISPLAY

1. 2. 3. Panel Description ............................................................................................................................. 9-2 Summary of Advice Displays ............................................................................................................ 9-3 Advice Displays ................................................................................................................................ 9-4
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CHAPTER 10: TEST MODE

Test Mode .................................................................................................................................................. 10-2 1. 2. 3. 4. 5. 6. Testing Sensor and Switch ........................................................................................................... 10-3 Testing Motor and Solenoid ........................................................................................................... 10-4 Sequential Operation Test ............................................................................................................. 10-4 Data Display .................................................................................................................................. 10-5 Data Clear ...................................................................................................................................... 10-5 Data Setting ................................................................................................................................... 10-6
CHAPTER 11: ELECTRICAL-COMPONENT LIST

1. 2. 3. 4. Motors ............................................................................................................................................. 11-2 Clutches .......................................................................................................................................... 11-3 Sensors .......................................................................................................................................... 11-4 Switches, and Counter ................................................................................................................... 11-7
CHAPTER 12: DESCRIPTION OF PCBs

1. 2. 3. 4. 5. Block Chart .................................................................................................................................... 12-2 Location of PCBs ........................................................................................................................... 12-3 Main PCB ....................................................................................................................................... 12-4 Power-Supply Unit ....................................................................................................................... 12-10 Panel PCB ................................................................................................................................... 12-12
CHAPTER 13: TIMING CHARTS

1. 2. 3. 4. 5. 6. 7. 8. 9. Power-ON Initialization Operation ................................................................................................. 13-2 Sub-Tower-Initialization Operation ................................................................................................ 13-3 Outline Operation of Test Collation 1 ............................................................................................ 13-5 Outline Operation of Test Collation 2 ............................................................................................ 13-8 Outline Operation of Collation 1 ................................................................................................... 13-11 Outline Operation of Collation 2 .................................................................................................. 13-15 Paper-Feed Bin-Switching Operation in Semiactive Mode ......................................................... 13-18 Detailed Operation of Test Collation 1 ........................................................................................ 13-21 Detailed Operation of Collation 1 ................................................................................................ 13-23
10. Detailed Operation of Collation 2 ................................................................................................ 13-25
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CHAPTER 1: MAINTENANCE
Contents
1. Preface ............................................................................................................................. 1-2 CAUTION .......................................................................................................................... 1-3 WARNING ......................................................................................................................... 1-4 2. 3. 4. Work Precautions ............................................................................................................ 1-5 Installation ....................................................................................................................... 1-7 Exterior Cover Removal ................................................................................................. 1-11
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CHAPTER 1. MAINTENANCE PREFACE
1.
Preface
This manual provides Technical Service Information for the RISO COLLATOR TC Series. This manual is published as a reference guide for use by RISO Group (RISO Kagaku Corp./RISO,INC./ RISO EUROPE Ltd./...) Certified Technical Representatives experienced in duplicator repair and service. This manual also provides procedures for removing and installing major components. Following these procedures will minimize machine malfunctions. This information and format will also increase technical representatives awareness and experience regarding repairs necessary to insure end-user satisfaction.
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CHAPTER 1. MAINTENANCE
CAUTION
[Handling of Lithium Battery] - Never fail to follow the following instructions when you discard the used lithium battery. 1. Never let the battery short-circuited. If the (+) and (-) terminals contact each other or metal materials, the battery will be short-circuited. If the batteries are collected and stored inorderly or one upon another, the above-mentioned case will occur. - DANGER If the battery is short-circuited, it will heat up and may in some cases explode into fire. 2. Never heat up the battery. - DANGER If you heat the battery up to more than 100C or put it into the fire, it may burn dangerously or explode. 3. Never disassemble the battery or press it into deformation. - DANGER If you disassemble the battery, the gas pouring out of the inside may hurt your throat or the negative lithium may heat up into fire. If the battery is pressed into deformation, the liquid inside may leak out of the sealed part or the battery may be short-circuited inside an explode. 4. Never fail to keep the battery out of reach of children. If you put the battery within reach of children, they may swallow it down. Should they swallow the battery, immediately consult the doctor. [Replacement of the Lithium Battery] 1. The lithium battery must be replaced by a trained and authorized service technician. 2. The battery must be replaced only with the same or equivalent type recommended by the manufacturer. 3. Discard used batteries according to the manufacturers instructions.
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CHAPTER 1. MAINTENANCE
!! WARNING !!
Important Safety Precautions 1. Always disconnect electrical supply before placing hands in the machine.
I. To avoid injuries: Be sure to disconnect the electrical power before disassembling, assembling,or when making adjustments on the machine. II. Protection of the machine: Make sure to turn OFF the power to the machine before plugging or unplugging the electrical connectors, or when connecting a Meter.
2. Always connect electrical connectors firmly.

I. To avoid electrical failure: The connectors must be connected firmly together and onto the PCBs. Press on the ends of the connectors and then on the middle to ensure a firm fit. II. Protection of the electrical components: The electrical components may be damaged due to short circuits caused by a loose connector.
Wire harness connector
FIRST
Press the ends.
THEN
Press the center, firmly.
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CHAPTER 1. MAINTENANCE WORK PRECAUTIONS
2.
Work Precautions
Inspection
If you discover any defects or problems during an inspection, fix the problems or if necessary take steps such as replacing a part.
Removal
Check the problem area. At the same time, examine the cause of the problem and determine whether the part needs to be removed or disassembled. Next proceed according to the procedures presented in the Technical Manual. In cases where, for example, it is necessary to disassemble areas with large numbers of parts, parts which are similar to each other, or parts which are the same on the left and right, sort the parts so that you do not mix them up during reassembly. (1) Carefully sort the removed parts. (2) Distinguish between parts which are being replaced and those which will be reused. (3) When replacing screws, etc., be sure to use the specified sizes. Half pierce section
Assembly and Installation

Unless specified otherwise, perform the removal procedures in reverse during assembly and installation. In cases where protrusions or holes are provided to assist in positioning parts, use them for accurate positioning and securing. (Protrusions and holes for positioning parts section) Half pierce
Tools
Using tools other than those specified can lead to injury or damage screws and parts. Have all the tools necessary for the work available.
Type
Tip size No. 2 No. 2 No. 2 No. 1 6 mm 3 mm 1.8 mm 8 mm 7 mm 2.5 mm 5 mm 8 mm 5.0 mm 4.0 mm 3.0 mm 2.5 mm 2.0 mm 1.5 mm
Shaft length, etc. (250 mm) (100 mm150 mm) (stubby type) (75 mm100 mm) (100 mm150 mm) (100 mm150 mm) (precision type) (100 mm150 mm) (100 mm150 mm)
Type Steel scale Gap gauge Radial cutting pliers Pliers Nipper Small flashlight Multimeter Soldering iron
Remarks 150 mm
Phillips screwdriver
Standard screwdriver Nut driver (box driver) High frequency driver Spanners (may be double-ended)
20 W30 W Flat, round
5.5 mm 10 mm Monkey
7 mm 13 mm
File
Hex wrenches
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CHAPTER 1. MAINTENANCE WORK PRECAUTIONS

[Standard Tool list]
Electrical system work

After removing wire bundles, fasten them with wire bundle bands (bar lock ties) so that they will not sag. When installing parts, be careful to avoid pinching or damaging the wire bundles. If a fuse blows, always replace it with one with the specified capacity. Using a fuse with a larger capacity can not only damage parts, but may cause fires. Be careful not to drop image scanners, thermal print heads, and other sensors as Wire bundle bands (bar lock ties)
they can be easily damaged.
Sensor types
Photo-electric sensors may be broadly divided into the following four types: interrupt types (U-shaped), actuator types, reflective types, and transmittive types. Magnetic sensors use Hall ICs, which react to the magnetic force in magnets. Always turn off the power before plugging or unplugging sensor connectors. Interrupt type
Light emitting unit
Actuator type
Light receiving unit
Light emitting unit Light emitting unit
Reflective type
Light emitting unit
Transmittive type
Switch types
Microswitches may be divided between normally open (NO) types and normally closed (NC) types. With an NO connection, an internal contact is connected when the switch actuator is pressed. With an NC connection, an internal contact is disconnected when the switch actuator is pressed. Magnetic lead switches are switches in which an internal contact is connected in reaction to the magnetic force of a magnet.
N.C. N.O.
N.C. N.O. Common terminal Common terminal
OFF state
ON state
Magnet
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CHAPTER 1. MAINTENANCE INSTALLATION
3.
Installation
RISO Collator TC5100 Installation Procedure

Packing List
The following parts are included in this package. 1. TC main body ....................................... 1 unit 2. Paper receiving unit .............................. 1 unit 3. Paper feed tray ...................................... 10 pcs 4. TC base support A ................................ 1 pc 5. TC base support B ................................ 4 pcs 6. TC base support C ................................ 1 pc 7. Paper arranger A5 ................................. 1 pc 8. Paper arranger A4 ................................. 1 pc 9. Rear cable cover ................................... 1 pc 10. Paper receiving unit support F ............. 1 pc 11. Paper receiving unit support R ............. 1 pc 12. Power cord ............................................ 1 pc 13. Screws .................................................. 1 set 14. User's guide .......................................... 1 copy 15. Installation guide (This manual) .......... 1 copy 16. Declaration of Conformity (*for EU only) ...................................... 1 copy CAUTION To avoid personal injury, take extra care in handling the TC main body. Because it weighs approx. 60kg. Nobody but Riso-authorized service representatives is allowed to install the this unit.
The following items (unbundled) are also required when installing the collator with the dedicated stand. 1. TC Stand ............................................... 1 unit 2. TC securing bracket ............................. 1 pc 3. Stand support A .................................... 4 pcs 4. Stand support A bracket ........................ 4 pcs 5. Stand support B .................................... 1 pc 6. Stand support B bracket ....................... 1 pc 7. Stand support housing .......................... 2 pcs 8. Screws .................................................. 1 set
= With the dedicated stand =

1.
Stand support A bracket
Place the stand upside down. Secure the Stand support A brackets to the stand (4 points) as illustrated. (Washered screw M6x10, 16 pcs)
2.
3.
Combine the Stand support B with the Stand support B bracket and secure the bracket to the stand as illustrated. (Washered screw M6x10, 4 pcs)
Important ! Be sure to place the Stand support B on the right
Stand support B Stand support A bracket Stand support B bracket
hand facing the front opening of the stand.
Shaft
Stand support A bracket
4.
Hang the hooks of the Stand support A on the shafts of the Stand support A brackets and secure the stand supports to the brackets with screws. (Washered screw M6x10, 8pcs)
Stand support A This document is printed on recycled paper.
028-06003-002
17 TC (Version 1.0)
5.
Stand support housing
Secure the Stand support housings to the stand as illustrated. (Washered screw M6x10, 4 pcs)
6.
Turn the stand on its feet.

Important ! Lock the casters to keep them from moving. Two casters on the left are lockable.
7.
Use holes nearer to the center on the stand.
Secure the TC securing bracket to the stand top board by inserting screws into the screw holes from under the board. (Washered screw M6x10, 4 pcs)
NOTE :Use four holes which are nearer to the center on the stand top board.
TC Securing bracket
Washered screw M6x10, 4 pcs
8.
Washered screw M6x10, 4 pcs
Place the TC main body on the stand adjusting its rubber feet to the four dents which are nearer to the center on the stand.
9.
Place on the dents nearer to the center on the stand.
Secure the bottom of the TC main body to the TC securing bracket on the stand matching the corresponding screw holes on both sides. (Washered screw M6x10, 4 pcs)
Important ! The following steps are required when the stand is moved after the above installation procedure.
i) Remove the Stand support B. ii) Remove the securing screws of the Stand support A and slide all feet into the Stand support housings. iii) Replace the securing screws into the other holes on the bracket as illustrated to keep the Stand supports from sliding out of the housing.
Stand support A Stand support A bracket
18 TC (Version 1.0)
= Without the dedicated stand =

1. Secure the TC base supports A, B, and C to the base of the TC Main body as illustrated.
TC base support A (with Binding screws M4x6 4pcs.) TC base support B
TC base support B (with Binding screws M4x6 2 pcs. each)
TC base support C (with Double-washered screws M4x8 3 pcs.)
= Setting up the TC5100 =

1.
Paper receiving unit support R
Secure the Paper receiving unit support F and R to the base of the TC main body. (Double-washered screw M3x8, 4 pcs)
Paper receiving unit support F
2.
Hang the arm hooks of the Paper receiving unit on the bars on the inner frame of the TC main body.
Paper receiving unit
3.
Adjust the height of the Paper receiving unit using the adjusters located on the bottom of the unit.
4.
Secure the Paper receiving unit to the TC main body with screws. (Binding screw M4x6, 2 pcs)
19 TC (Version 1.0)
5.
Connect the cable extending from the Paper receiving unit to the TC main body and cover it with the Rear cable cover. (Binding screw M3x6, 2 pcs)
Important ! The Off-set stacking guides do not work unless the cable is connected.
Rear cable cover
6.
Paper feed tray
Set the Paper feed trays orderly from bottom to top.
7.
Connect the Power cord and turn on the power switch. Confirm that the collator works appropriately.
CHAPTER 1. MAINTENANCE EXTERIOR COVER REMOVAL
4.
Exterior Cover Removal
A: Front cover
(Bind-head Screw, M4 x 8 7 pcs)
B: Sensor cover (Bind-head Screw, M4 x 8 4 pcs)
C: Rear cover
(Bind-head Screw, M4 x 8 11 pcs)
D: Rear cable cover (Bind-head Screw, M3 x 8 2 pcs)
G H
E: Stabilizer F: Motor cover
(Bind-head Screw, M4 x 8 4 pcs) (Bind-head Screw, M3 x 8 4 pcs)
G: Connector cover 2(Bind-head Screw, M3 x 8 4 pcs) H: Connector cover 1(fastened together with the sensor cover)
CHAPTER 2: MACHINE SUMMARY
Contents
1. 2. 3. 4. Features ........................................................................................................................... 2-2 Specifications .................................................................................................................. 2-3 Product Configuration ...................................................................................................... 2-4 Cross-Sectional View ...................................................................................................... 2-5
21 TC (Version 1.0)
CHAPTER 2. MACHINE SUMMARY FEATURES
1.
Features
1. 2. 3. 4. 5. 6. Maximum processing speed of 60 sets/min. Capable of collating 120 sets of documents with 10 A4size pages each, in no more than two minutes (previously 55 sets/min.). The Wing Sort Method, in which the two wings of the paper-receiving area are moved alternately, has been newly adopted. The machine sorts sets individually, alternately to the left and right. Capable of holding 280 sheets of paper in each bin simultaneously (previously 260 sheets) Capable of collating paper one size larger (320 mm x 450 mm) than A3 size (297 mm x 420 mm) (previously up to A3 size) Newly equipped with a back-lit LCD display. The machine also comes equipped with an operation panel that makes collating easy. High-precision sensors detect collation errors. The locations of errors and other details are indicated on the LCD display.
22 TC (Version 1.0)
CHAPTER 2. MACHINE SUMMARY SPECIFICATIONS
2.
M odel Type
Specifications
TC 5100 D eskt op w i t hf ul lpanel key cont r ol 10 bi ns Mi ni m um :148m m x 182m m ( 5. 9" x 7. 2" ) / A5 M axi m um :320m m x 450m m ( 12. 5" x 17. 7" ) / A3 ( Ledger ) 14l b bond) Mi ni m um :52 g/ m2 ( 34l b bond) M axi m um :128 g/ m2 ( l b bond paper ) 28 m m ( appr ox.280 sheet s of64 g/ m 2 or 17A ppr ox.70m m ( 2. 8" ) t hi ck st ack ofsheet s Si ngl e U ni tM ode:3 speed set t i ng; Sl ow speed ( 33 set s/ mi n. ) ,st andar d( 40 set s/ mi n. ) ,and Fastspeed ( 60 set s/ mi n. ) Al lspeeds ar ef orA 4 sheet sf ed l engt hw i se. Swi ng m ode,st r ai ghtm ode ( of f setw i t h m ovabl e wi ngs on t he R ecei verFl anker s) St andar d m ode St andar d m ode Tab S heetI nser t i on m ode and sem i act i ve ( D oubl e C ycl e)m ode LE D and LC D di spl ays f orS heetP r esence/ A bsence,M i sf eed,D oubl e Feed, P aperJam ,and Tr anspor tB el tC overO pen 4 di gi t s( A ddi t i on m ode)or3 di gi t s( S ubt r act i on m ode)I nt er act i ve LC D ( 3 di gi ti nputi n Tab S heetI nser t i on m ode) M ovabl e wi ngs i nt he paper r ej ect i ongui de ar ea St acki ng m odes ( Swi ng and S t r ai ghtm odes) ,S heetFeed m odes ( St andar d, Tab S heetI nser t i on,and D oubl e C ycl e m odes) ,P r ocess S peed ( 3 speed set t i ngs) ,E r r or Di spl ays,Var i abl e P aperP r essur e, A ddi t i on/ S ubt r act i on m odes f ort he C ount er ,D oubl e Feed D et ect i on O n/ Of f . ( 110v M O D E L) 110 120V A C ,60 H z <1. 2A > ( 220v M O D E L) 220 120V A C ,60 H z <0. 8A > W hen pl aced on t he t abl et op:861 m m x 631 m m x 1031 m m ( 33. 9" x 24. 9" x 40. 6" ) W hen pl aced on t he dedi cat ed st and:921m m x 887m m x 1529 m m ( 36. 3" x 35. 0" x 60. 2" ) W hen t w o uni tar ej oi nt ed:2082 m m x 887m m x 1529 m m ( 82. 0" x 35. 0" x 60. 2" ) W hen one uni tst ands:72 kg ( 159l bs. ) W hen t w o uni t s ar ej oi nt ed:208 kg ( 459l bs. )w i t ht he dedi cat ed st ands 15 C t o 30 C ( 59 F t o 86 F)w i t h 40% t o 70% ( noncondensi ng)
N um ber ofbi ns P aper si ze P aper w ei ght Bi ns C apaci t y R ecei vi ng t r ay capaci t y
C ol l at i ng speed
St acki ng m odes S heet f eed m odes D et ect i on f unct i on Di spl ay Sw i ng m et hod Var i ous f unct i ons
P ow er S uppl y <R equi r em ent s> Di m ensi ons [ W x D x H] W ei ght O per at i on t em per at ur e and hum i di t y
23 TC (Version 1.0)
CHAPTER 2. MACHINE SUMMARY PRODUCT CONFIGURATION
3.
Product Configuration
(1) Main unit
Riso Collator TC5100 Riso Collator TC3100 (insertion mode and semiactive mode not available)
(2) Accessories
Paper arranger A4 Paper arranger A5 Power cord Users Guide Declaration of Conformity (* for EU only)
(3) Options
Dedicated stand Joint unit Riso stage cleaner
(4) Consumables
Stripper plate for replacement Feed-roller assembly for replacement Feed-roller assembly for woody paper
24 TC (Version 1.0)
CHAPTER 2. MACHINE SUMMARY CROSS-SECTIONAL VIEW
4.
Cross-Sectional View
D C B A
[1] [2] E
G J H [3] I [4]
A: Paper tray B: Feed roller C: Stripper plate D: Transport roller E: Support roller [1] Paper-feed area [2] Vertical-transport area [3] Paper-ejection area [4] Stacker area
F: Transport belt G: Gate H: Ejection roller (upper) I: Ejection roller (lower) J: Paper-ejection wing Individually feeds the paper loaded into the paper tray of each bin Transports the paper arriving from the paper-feed area to the paperejection area while collating it Feeds the collated paper arriving from the vertical-transport area to the stacker area Loads the collated paper in accordance with the preset stacking mode (swing stack or straight stack) 25 TC (Version 1.0)
CHAPTER 2. MACHINE SUMMARY CROSS-SECTIONAL VIEW
[Memo]
26 TC (Version 1.0)
CHAPTER 3: MAIN-UNIT DRIVE AREA
Contents
Mechanism ............................................................................................................................ 3-2 1. 2. Drive-Area Rotating Mechanism ............................................................................... 3-2 Main-Motor Safety Mechanism .................................................................................. 3-3
Disassembly .......................................................................................................................... 3-4 1. 2. 3. Removal of the Main Belt .......................................................................................... 3-4 Removal of the Main Motor ....................................................................................... 3-5 Removal of the Main-Motor Safety Switch ................................................................ 3-6
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CHAPTER 3. MAIN-UNIT DRIVE AREA DRIVE-AREA ROTATING MECHANISM
Mechanism 1. Drive-Area Rotating Mechanism

When main motor [A] starts running, its rotation is transmitted to main belt [B] and pulley B [C] in order to turn drive belt [D].
A: Main motor B: Main belt C: Pulley B D: Drive belt
CHAPTER 3. MAINTENANCE MAIN-MOTOR SAFETY MECHANISM
2.
Main-Motor Safety Mechanism

The main motor is designed to start running only when the main-motor safety switch [A] is turned on.
A: Main-motor safety switch
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CHAPTER 3. MAIN-UNIT DRIVE AREA REMOVAL OF THE MAIN BELT
Disassembly 1. Removal of the Main Belt

Removal
(1) Reduce the tension of the drive belt. Remove spring [A]. Loosen the screws of tension plate [B] (three pan-head screws W, M3 x 8). (2) Remove connection plate [C] (two pan-head screws W, M3 x 8). (3) Remove tension spring [D], and loosen the screws of tension plate assembly [E] (two pan-head screws W, M3 x 8). (4) Remove the main-motor shaft plate [F] (three hexagonal-head RS Tights, M3 x 6). (5) Remove the E-ring and screws of the transport-roller bearing plate [G] (two hexagonal-head RS Tights, M3 x 6). (6) Remove main belt [H]. [Precautions on Reassembly] Fasten tension plate [B] and tension-plate assembly [E] with the spring hooked.
G C D
A: Transport-belt spring B: Tension plate C: Connection plate D: Main-belt spring E: Tension-plate assembly F: Main-motor shaft plate G: Transport-roller bearing plate H: Main belt
H F
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CHAPTER 3. MAINTENANCE REMOVAL OF THE MAIN MOTOR
2.
Removal of the Main Motor

Removal
(1) Remove plug socket cover [A]. (2) Remove the main belt. Perform the work described in the preceding subsection (1. Removal of Main Belt). (3) Unplug two connectors (drive side) [B] from the main motor, followed by the two main-motor connectors (inside the machine) (Fig. 1). (4) Remove the four cap screws, followed by the main motor [C]. (Four sets of cap screws, M5 x 20 + spring washer f5 + plain washer (5) [Precautions on Reassembly] When reinstalling the main motor, position it with its wire bundle facing down (bottom-plate side) (Fig. 3).
A C B
A: Plug socket cover B: Main-motor connectors (Drive side) C: Main motor Fig. 1
Fig. 2
Fig. 3
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CHAPTER 3. MAIN-UNIT DRIVE AREA REMOVAL OF THE MAIN-MOTOR SAFETY SWITCH
3.
Removal of the Main-Motor Safety Switch

Removal
(1) Remove top cover [A] (six hexagonal-head RS Tights, M4 x 6). (2) Unplug the connector of the main-motor safety switch [B]. (3) Remove the main-motor safety switch [B] (two pan-head screws W, M3 x 15).
A: Top cover B: Main-motor safety switch
36 TC (Version 1.0)
CHAPTER 4: PAPER-FEED AREA
Contents
Mechanisms .......................................................................................................................... 4-2 1. 2. 3. 4. Paper-Tray Mechanism ............................................................................................ 4-2 Paper-Tray Elevating Mechanism ............................................................................ 4-3 Paper-Feeding Mechanism ...................................................................................... 4-5 Paper-Feed Stripping Mechanism ........................................................................... 4-6
Disassembly .......................................................................................................................... 4-7 1. 2. 3. 4. 5. 6. 7. 8. 9. Removal of feed rollers ............................................................................................ 4-7 Removal of the stripper plate ................................................................................... 4-7 Removal of paper-detection sensors ...................................................................... 4-8 Removal of Paper-Feed Detection Sensors ............................................................ 4-9 Removal of Paper-Feed Clutches ......................................................................... 4-10 Removal of the Elevator Motor ................................................................................ 4-11 Removal of Paper Trays ........................................................................................ 4-12 Removal of Guide Plates ....................................................................................... 4-14 Removal of the Transport Roller ........................................................................... 4-15
10. Removal of the Drive Belt ...................................................................................... 4-16
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CHAPTER 4. PAPER-FEED AREA PAPER-TRAY MECHANISM
Mechanisms
1. Paper-Tray Mechanism
Detection of the collation-paper setting
Each bin of the paper tray is checked for the presence or absence of paper by paper-detection sensor [A] (actuator type). Paper-detection sensor [A] determines the bin of the paper tray in which the paper is currently loaded for operation. If the paper loaded in the bin checked above runs out during the collating operation, the machine will stop collating.
Setup of guides
Move feed guide 1 (moving) [B] to the right until it contacts the left end face of the paper. Feed guide 2 [C] is a fixed component, and paper should be loaded into it aligned to the right. If long paper such as A3 size is to be handled, keep tray extension [D] extended. Tray extension [D] comes attached to the paper tray.
Error indications
If there is no paper loaded in any of the paper-tray bins, pressing <CHECK> will cause the message [ADD PAPER] to appear. The LED indicating the paper setting on the panel, as well as the LEDs of all paper-tray bins, will also light up. Similar indications will be given if paper runs out in any of the occupied bins during collating operation, and the LED of the relevant bin that is out of paper will light up.
A B
D
A: Paper-detection sensor B: Feed guide 1 (moving) C: Feed guide 2 D: Tray extension
42 TC (Version 1.0)
CHAPTER 4. PAPER-FEED AREA PAPER-TRAY ELEVATING MECHANISM
2.
Paper-Tray Elevating Mechanism

Ascent/descent
The paper tray is raised or lowered by the operation of elevator motor [A] located on the drive side, which is activated when lift lever [B] is moved up or down. The top stopping position of the paper tray is detected by elevator upper-limit sensor [C]. The bottom stopping position of the paper tray is detected by elevator lower-limit sensor [D].
A
A: Elevator motor B: Lift lever C: Upper-limit sensor D: Lower-limit sensor
43 TC (Version 1.0)
CHAPTER 4. PAPER-FEED AREA REMOVAL OF THE MAIN BELT
Descending motion
Motion started [1] Elevator Lower-limit sensor
Motion ended
Light received (OFF) [2] Error after 7 sec or more
Light blocked (ON)
Elevator motor
Lowering rotation
Stopped
Explanation of Motions [1] [2] After its motion is started, the elevator motor rotates to lower the paper tray until the lower-limit sensor comes on. If the OFF state of the lower-limit sensor lasts for seven seconds or more following the start of rotation of the elevator motor, an elevator-motor lock error will be issued. The elevator motor will be stopped and [E-02] will be displayed. If an overcurrent flows for 0.8 sec or more during the motion of the elevator motor, the motor will be stopped and [E-02] will be displayed.
[3]
Ascending motion
Motion started [1]
Motion ended
Elevator upper-limit sensor
Light received (OFF) [2] Error after 7 sec or more
Light blocked (ON)
Elevator motor
Raising rotation
Stopped
Explanation of Motions [1] [2] After its motion is started, the elevator motor rotates to raise the paper tray until the upper-limit sensor comes on. If the OFF state of the upper-limit sensor lasts for seven seconds or more following the start of rotation of the elevator motor, an elevator-motor lock error will be issued. The elevator motor will be stopped and [E-02] will be displayed. If an overcurrent flows for 0.8 sec or more during the motion of the elevator motor, the motor will be stopped and [E-02] will be displayed.
[3]
44 TC (Version 1.0)
CHAPTER 4. PAPER-FEED AREA PAPER-FEEDING MECHANISM
3.
Paper-Feeding Mechanism
Paper-Feed Mechanism
Paper is transported by the rotation of feed rollers [A]. Feed rollers [A] rotate as the drive force of the main motor is transmitted to them through paper-feed clutch [B]. Paper-feed detection sensors [C] determine whether the paper is being transported normally, and whether there is a double feed, misfeed, or paper jam.
A: Feed rollers B: Paper-feed clutch C: Paper-feed detection sensors
45 TC (Version 1.0)
CHAPTER 4. PAPER-FEED AREA PAPER-FEED STRIPPING MECHANISM
4.
Paper-Feed Stripping Mechanism

Stripping Mechanism
The paper loaded into the paper tray is stripped by feed rollers [A] and stripper plate [B], and only the top sheet is fed into the machine. The stripping pressure can be varied in two steps by turning the paper-feed pressure-adjustment cam [C]. The paper-feed pressure can also be varied in two steps by actuating the paper pressure-adjustment lever [D].
C B
Heavy
Standard
A: Feed rollers B: Stripper plate C: Paper-feed pressure-adjustment cam D: Paper pressure-adjustment lever
46 TC (Version 1.0)
CHAPTER 4. PAPER-FEED AREA REMOVAL OF FEED ROLLERS
Disassembly
1. Removal of feed rollers
Removal
[1] Push paper-feed roller assembly [A] in the direction of [1], and remove it in the direction of [2].
[1] [2]
A: Feed-roller assembly B: Feed roller C: Feed-roller shaft
2.
Removal of the stripper plate

Removal
[1] [2] Remove feed-roller assembly [A]. Remove stripper plate [D] from stripper support plate [E] in the paper-feed area.
[Precautions on Reassembly] [1] When installing stripper plate [D] on stripper support plate [E] in the paper-feed area, push it in all the way until you feel a click as it locks in snugly.
D E
D: Stripper plate E: Stripper support plate
47 TC (Version 1.0)
CHAPTER 4. PAPER-FEED AREA REMOVAL OF PAPER-DETECTION SENSORS
3.
Removal of paper-detection sensors

Removal
[1] [2] [3] [4] Lift paper tray (fixing part) [A] and detach it from bin pivot [B]. Remove paper-detection-sensor cover [D] (one pan-head screw W, M3 x 6). Unplug the connector of paper-detection sensor [C]. Remove paper-detection sensor [C] (one binding-head screw, M3 x 6).
[Precautions on Reassembly] [1] [2] Exercise care to prevent the actuator of paper-detection sensor [C] from being caught on the paper tray. When reassembling paper-detection sensor [C], make sure the screws go in straight when they are tightened.
* Following reassembly, the actuator must operate smoothly without striking the paper tray.
A B
Enlarged view
D
A: Paper tray (fixing part) B: Bin pivot C: Paper-detection sensor D: Paper-detection-sensor cover
48 TC (Version 1.0)
CHAPTER 4. PAPER-FEED AREA REMOVAL OF PAPER-FEED DETECTION SENSORS
4.
Removal of Paper-Feed Detection Sensors

Removal
[1] [2] [3] Open door [A] and detach guide plate 2 [B] (one hexagonal-head RS Tight, M3x6). Remove guide plate 2 [B] by moving it toward the panel side. Unplug the two connectors from paper-feed detection sensor [D]. Loosen the cap screw of the feed-detection sensor plate [C], and move the sensor upward to remove it.
* The boss of the door stopper can only be removed at bins 9 and 10. The top part is fitted with only a light-receiving device for bin 1, and the intermediate tiers are each fitted with a light-emitting device for the bin immediately above and a light-receiving device for the bin immediately below. The bottom part is fitted with a light-emitting device for bin 10 and the light-receiving device of the paper-ejection sensor. [Precautions on Reassembly] After the paper-feed detection sensors have been replaced, the automatic light adjustment must be made on the paper-feed detection sensors in Test Modes Nos. 201 through 210.
Cap screw
A: Door B: Guide plate 2 C: Feed-detection sensor plate
49 TC (Version 1.0)
CHAPTER 4. PAPER-FEED AREA REMOVAL OF PAPER-FEED CLUTCHES
5.
Removal of Paper-Feed Clutches

Removal
The paper-feed clutches are installed in a set for every other bin. [1] [2] [3] [4] Remove the feed-roller assemblies for each pair of bins (page 4-7). Unplug the connector of paper-feed clutch [A]. Remove bracket [B], taking care not to misplace the pieces metal (two hexagonal-head RS Tights, M3 x 6). Remove white washer [C], paper-feed clutch [A], and shaft [D] (one pan-head screw W, M3 x 6), taking care not to misplace the white washer.
* When reinstalling the clutches, check the engagement between the bracket and the whirl-stop parts of the clutch.
Whirl-stop parts of the clutch
A: Paper-feed clutch B: Bracket C: Washer D: Shaft
C
CHAPTER 4. PAPER-FEED AREA REMOVAL OF THE ELEVATOR MOTOR
6.
Removal of the Elevator Motor

Removal
[1] [2] [3] [4] [5] [6] Switch off the machine with the paper trays raised. Unplug the connector of elevator motor [A]. Remove motor bracket [B] (four hexagonal-head RS Tights, M3 x 6). Remove the E-ring from gear assembly [C], and detach the elevator motor unit. Loosen the set screw of elevator-motor gear [D] to detach it from elevator motor [A]. Remove the elevator motor [A] from motor bracket [B] (two pan-head screws W, M3 x 6).
D A
A: Elevator motor B: Motor bracket C: Gear assembly D: Elevator-motor gear
CHAPTER 4. PAPER-FEED AREA REMOVAL OF PAPER TRAYS
7.
Removal of Paper Trays

Removal
[1] [2] [3] Switch off the machine with the paper trays raised, and detach the rear cover. Lift the paper tray (fixing part) to remove it from the bin pivot. Unhook the two bin spring wires [A] of the paper pressure-adjustment lever from rollers [B] (Figs. 1 & 2).
Fig. 1
Fig. 2
[4]
Open the main PCB bracket as follows: Remove the set screws from the main PCB bracket [D] (Fig. 3) (three binding-head screws, M3 x 6). Remove fixing screw [C] from the power-supply-unit grounding wire (one binding-head screw, M4 x 6).
Enlarged view Bind-head screws are located on the rear of the main PCB bracket (paper-tray side).
Enlarged view Fig. 3
CHAPTER 4. PAPER-FEED AREA REMOVAL OF PAPER TRAYS

Remove stacker connector plate [E] (two hexagonal-head RS Tights, M3 x 6). Pull out the wire bundle from the clamped-wire saddle, and open main PCB bracket [D].
[5] [6]
Unplug connector [F] from the paper-detection sensor on the rear of the main PCB, and insert that wire bundle into the paper-tray side. Remove paper tray [G] (one binding-head screw and one pan-head screw W, M4 x 6 each).
A: Bin spring wire B: Roller C: Grounding-wire fixing screw D: Main PCB bracket E: Stacker connector plate F: Paper-detection-sensor connector G: Paper tray 4 13 TC (Version 1.0)
CHAPTER 4. PAPER-FEED AREA REMOVAL OF GUIDE PLATES
8.
Removal of Guide Plates

Removal
[1] [2] [3] [4] [5] [6] Detach the rear cover. Remove the feed-roller assembly (4-7). Open transport-area door [A], remove two hinge shafts [B] using one E-ring each, and detach transport-area door [A]. Remove guide plate 2 [C]. Remove the paper-feed detection sensor (4-9). Remove guide plate [D] by removing the two pan-head screws SW.W.
Important and Caution: * For bin 2 and bin 9, the magnet catch plate of the transport-area door must be removed in advance from the panel side. Do NOT remove the screws from the stripper plate or the plate on which the paper-feed detection sensor is located. The mounted position of said plate determines the paperfeeding performance, and a special jig is required to adjust that position.
B C
A: Transport-area door B: Hinge shaft C: Guide plate 2 D: Guide plate 4 14 TC (Version 1.0)
CHAPTER 4. PAPER-FEED AREA REMOVAL OF THE TRANSPORT ROLLER
9.
Removal of the Transport Roller

Removal
[1] [2] Remove the guide plate (4-14). Reduce the tension of drive belt [A] as follows: Remove spring [B] and loosen the three screws of tension plate [C]. [3] [4] Remove transport-roller pulley [D] using the E-ring. Remove transport roller [E] using the E-ring and two bearings.
B C A
A: Drive belt B: Spring C: Tension plate D: Transport-roller pulley E: Transport roller
CHAPTER 4. PAPER-FEED AREA REMOVAL OF THE DRIVE BELT
10. Removal of the Drive Belt

Removal
[1] [2] [3] [4] Remove the main belt (3-4). Remove the paper-feed clutches from all bins (4-10). Reduce the tension of drive belt [A] (4-15 [2]). Remove drive belt [A].
CHAPTER 5: VERTICAL-TRANSPORT AREA
Contents
Mechanisms .......................................................................................................................... 5-2 1. 2. Vertical-Transport Mechanism .................................................................................. 5-2 Main-Motor Safety Mechanism .................................................................................. 5-2
Disassembly .......................................................................................................................... 5-3 1. Removal of the Transport Belt .................................................................................. 5-3
51 TC (Version 1.0)
CHAPTER 5. VERTICAL-TRANSPORT AREA VERTICAL-TRANSPORT MECHANISM
Mechanisms
1. Vertical-Transport Mechanism
This mechanism grasps a sheet arriving from the paper-feed area between transport roller [A] and transport belt [B], and transports it to the paper-ejection area while collating it. Transport roller [A] rotates constantly while the main motor is running. Transport belt [B] runs along with transport roller [A]. When both door-open switch (upper) [C] and door-open switch (lower) come on (detection of closing), the transport-area door is determined to be closed.
2.
Main-Motor Safety Mechanism

The main motor can start running only when main-motor safety switch [D] is on.
A: Transport roller B: Transport belt C: Door-open switch (upper)
D: Main-motor safety switch
52 TC (Version 1.0)
CHAPTER 5. VERTICAL-TRANSPORT AREA REMOVAL OF THE TRANPORT BELT
Disassembly
1. Removal of the Transport Belt
Removal
[1] [2] [3] [4] Remove cover (L/H) [A] (five pan-head screws SW.W, M3 x 6). Remove cover (R/H) [B] (five pan-head screws SW.W, M3 x 6). Remove transport-roller-plate unit [C] (six pan-head screws SW.W, M3 x 6). Remove transport belt [D].
[Precautions on Reassembly] When installing transport-roller-plate unit [C] on the door, make sure the various springs are positioned properly in the protruding sections on the door side.
A: Cover (L/H) B: Cover (R/H) C: Transport-roller-plate unit D: Transport belt
53 TC (Version 1.0)
CHAPTER 5. VERTICAL-TRANSPORT AREA REMOVAL OF THE TRANPORT BELT
[Memo]
54 TC (Version 1.0)
CHAPTER 6: PAPER-EJECTION AREA
Contents
Mechanism ............................................................................................................................ 6-2 Collated-Sheet Ejection Mechanism .............................................................................. 6-2 Disassembly .......................................................................................................................... 6-4 1. 2. 3. 4. Removal of Paper-Ejection Roller (upper) ............................................................... 6-4 Removal of Paper-Ejection Roller (lower) ................................................................ 6-6 Removal of Paper-Ejection Sensor (upper) ............................................................. 6-7 Removal of Paper-Ejection Sensor (lower) ............................................................. 6-8
61 TC (Version 1.0)
CHAPTER 6. PAPER-EJECTION AREA COLLATED-SHEET EJECTION MECHANISM
Mechanism
Collated-Sheet Ejection Mechanism
The paper collated in the vertical-transport area is sent to paper-ejection roller (upper) [B] and paperejection roller (lower) [C] along gate [A], and then transported to the stacker area by the rotation of paperejection roller (upper) [B] and paper-ejection roller (lower) [C]. When main motor [D] starts running, paper-ejection roller (upper) [B] rotates. Since paper-ejection roller (lower) [C] is pressed against paper-ejection roller (upper) [B] by spring [E], it rotates along with paperejection roller (upper) [B]. Moreover, paper-ejection sensors [F] and [G] ensure that the collated paper is ejected normally.
62 TC (Version 1.0)
CHAPTER 6. PAPER-EJECTION AREA COLLATED-SHEET EJECTION MECHANISMBCED
D E
A: Gate B: Paper-ejection roller (upper) C: Paper-ejection roller (lower) D: Main motor E: Spring F: Paper-ejection sensor (upper) G: Paper-ejection sensor (lower)
63 TC (Version 1.0)
CHAPTER 6. PAPER-EJECTION AREA REMOVAL OF PAPER-EJECTION ROLLER (UPPER)
Disassembly
1. Removal of Paper-Ejection Roller (upper)
[1] Remove the covers. Front cover (seven binding-head screws, M4 x 8) Rear cable cover (two binding-head screws, M3 x 6) Rear cover (11 binding-head screws, M4 x 8) Remove safety cover [A] (two binding-head screws, M3 x 6). Reduce the tension of main belt [F]. Remove connection plate [B] (two pan-head screws SW.W, M3 x 6). Remove tension spring [C]. Loosen the two screws (pan-head SW.W) of tension plate assembly [D]. [4] Remove bearing plate [E] and draw out the bearing (two hexagonal-head RS Tights, M3 x 6).
[2] [3]
64 TC (Version 1.0)
CHAPTER 6. PAPER-EJECTION AREA REMOVAL OF PAPER-EJECTION ROLLER (UPPER)

[5] [6] [7] Remove shaft [H] and spring [I] from tension plate [G] of the paper-ejection roller (lower) to free said roller. Remove the E-ring and draw out pulley [J] from the shaft. Remove the E-ring on both the front and rear sides, draw out bearing [K], and remove paper-ejection roller (upper) [L].
L
A: Safety cover B: Connection plate C: Tension spring D: Tension-plate assembly
E: Bearing plate F: Main belt G: Tension plate H: Shaft I: Spring J: Pulley K: Bearing L: Paper-ejection roller (upper)
65 TC (Version 1.0)
CHAPTER 6. PAPER-EJECTION AREA REMOVAL OF PAPER-EJECTION ROLLER (LOWER)
2.
Removal of Paper-Ejection Roller (lower)

[1] Remove the covers. Front cover Rear cable cover Rear cover Stabilizer Motor cover Remove shaft [B] and spring [C] from tension plate [A] (on the front and rear side). Remove the E-ring; draw out bearing [D], tension plate [A], and tension plate washer [E] from the shaft; and remove paper-ejection roller (lower).
[2] [3]
E A A D
A: Tension plate B: Shaft C: Spring D: Bearing E: Tension-plate washer
66 TC (Version 1.0)
CHAPTER 6. PAPER-EJECTION AREA REMOVAL OF PAPER-EJECTION SENSOR (UPPER)
3.
Removal of Paper-Ejection Sensor (upper)

[1] [2] [3] [4] [5] Open the door. Remove gate [A] (two pan-head screws W, M3 x 6, indicated by the arrow). Unplug connector [B] from the paper-ejection sensor (upper), and connector [C] from the paper-feed detection sensor. Loosen cap screw [D], move the paper-feed-detection-sensor bracket (upper) [E] downward, and remove the sensor together with the bracket. Detach paper-ejection sensor (upper) [F] from paper-feed-detection-sensor bracket (upper) [E] (two binding-head screws, M3 x 6).
[Precautions on Reassembly] Do not exert unnecessary force on the LED of the paper-feed detection sensor, as the sensor is fitted on the top surface of the paper-detection-sensor bracket (upper). Make sure the LED is securely fitted into the hole of the paper guide.
A: Gate B: Paper-ejection-sensor connector C: Paper-feed-detection-sensor connector D: Cap screw E: Paper-feed-detection-sensor bracket (upper) F: Paper-ejection sensor (upper)
67 TC (Version 1.0)
CHAPTER 6. PAPER-EJECTION AREA REMOVAL OF PAPER-EJECTION SENSOR (LOWER)
4.
Removal of Paper-Ejection Sensor (lower)

[1] Remove the covers. Rear cable cover Rear cover Stabilizer Motor cover Remove main motor [D]. (See 2. Removal of the Main Motor, Disassembly, in Chapter 3. Main-Unit Drive Area.) Unplug connector [E] from the paper-ejection sensor. Remove paper-ejection sensor (lower) [F] and sensor cover [G] (one binding-head screw, M3 x 6).
[2] [3] [4]
[Precautions on Reassembly] Match the notch of paper-ejection sensor (lower) [F] with the protruding section of the sensor bracket. Match the protruding section of sensor cover [G] with the hole of the paper-ejection-sensor bracket.
68 TC (Version 1.0)
A: Main belt B: Main-motor shaft plate C: Set screws D: Main motor E: Paper-ejection-sensor (lower) connector F: Paper-ejection sensor (lower) G: Sensor cover
69 TC (Version 1.0)
[Memo]
CHAPTER 7: STACKER AREA
Contents
Mechanism ............................................................................................................................ 7-2 1. 2. 3. 4. 5. Collated-Sheet Stacking Mechanism ....................................................................... 7-2 Paper-Ejection-Wing Mechanism ............................................................................ 7-4 Paper-Ejection-Wing Initializing Mechanism ........................................................... 7-8 Paper-Ejection-Wing Initializing Mechanism ........................................................... 7-9 Collated-Sheet Full-Detection Mechanism ........................................................... 7-10
Disassembly ........................................................................................................................ 7-11 1. 2. 3. 4. 5. 6. Removal of the Stacker Unit ................................................................................... 7-11 Removal of the Stacker Motor ................................................................................ 7-12 Removal of the Stacker Sensor ............................................................................. 7-13 Removal of the Stacker Home Sensor .................................................................. 7-13 Removal of the Full-Detection Sensor .................................................................. 7-14 Removal of the Full-Detection Sensor .................................................................. 7-15
71 TC (Version 1.0)
CHAPTER 7. STACKER AREA COLLATED-SHEET STACKING MECHANISM
Mechanism
1. Collated-Sheet Stacking Mechanism
This mechanism stacks collated sheets arriving from the paper-ejection area, in accordance with the preset paper-ejection mode. Two paper-ejection modes are available: the swing-stack mode and the straight-stack mode. When the machine is switched on, the swing-stack mode is activated by default. Pressing the paper-ejection-mode selector key enables the user to switch the swing-stack mode to the straight-stack mode or vice versa. When the swing-stack mode is active, the swing-stack-mode paper guide (L) setting position [F] of paper guide (L) [A] is matched to the collated-sheet size, paper guide (R) [B] is matched to the swing-stackmode paper guide (R) setting position [G], and stopper [C] is matched to the collated-sheet size, to enable collating operation. When collated sheets are ejected into the stacker area, the right and left ejection wings [D] open and close alternately for each sheet, thereby allowing the collated sheets to be stacked individually in the stacker area and swung by approximately 30 mm to the right and left. When a paper-ejection wing [D] opens, rear support [E] protrudes from paper guides [A] [B] to prevent the collated sheet from bouncing. In the straight-stack mode, the collating operation is conducted with the straight-stack-mode paper guide (L) setting position [H] of paper guide (L) [A] matched to the collated-sheet size, paper guide (R) [B] matched to straight-stack-mode paper guide (R) setting position [I], and stopper [C] to the collated-sheet size. Paper-ejection wing [D] does not operate, and the collated sheets are stacked in their own width.
72 TC (Version 1.0)
CHAPTER 7. STACKER AREA COLLATED-SHEET STACKING MECHANISM
A: Paper guide (L) B: Paper guide (R) C: Stopper D: Paper-ejection wing E: Rear support F: Swing-stack-mode paper guide (L) setting position G: Swing-stack-mode paper guide (R) setting position H: Straight-stack-mode paper guide (L) setting position I: Straight-stack-mode paper guide (R) setting position
73 TC (Version 1.0)
CHAPTER 7. STACKER AREA RAPER-EJECTION-WING MECHANISM
2.
Paper-Ejection-Wing Mechanism
As stacker motor [A] runs, main drive shaft [B] rotates, as does cam [C] attached to main drive shaft [B]. Drive arms [D] [E] move back and forth along the grooves of cam [C], and their motion is transmitted to arm shaft [F], causing support link [G] and paper-ejection wing [H] to open and close. The opening and closing states of the paper-ejection wing are detected by stacker sensor [I] and stacker home sensor [J]. Stacker sensor [I] detects which paper-ejection wing [H] is open, while stacker home sensor [J] detects which paper-ejection wing [H] is acting, as well as the state in which both paper-ejection wings [H] are closed.
Cam drive arm (L)
Cam drive arm (R)
Motor sensor area
J I
Motor sensor area (enlarged view)
74 TC (Version 1.0)
Cam drive arm (L) (enlarged view)
Cam drive arm (R) (enlarged view)
A: Stacker motor B: Main drive shaft C: Cam D: Drive arm (R) E: Drive arm (L)
F: Drive arm shaft G: Support link H: Paper-ejection wing I: Stacker sensor J: Stacker home sensor
75 TC (Version 1.0)
1. Right-Hand Motion
Paper-ejection-wing opening motion
Opening motion ended
Paper-ejection-wing closing motion

Closing motion ended
Ejection sensor
Paper detected (ON)
[1] The stacker motor starts running 100 mm (700 pulses) after the ejection sensor detects paper (ON).
No paper detected (OFF)
Stacker home sensor
OFF (Position of right-hand motion)
ON (Position of left-hand motion)
Stacker sensor [2] Error after 1 sec or more Stacker motor Starts running
ON (Stopping position) [2] Error after 1 sec or more Stopped Starts running Stopped
[2] The stacker motor stops running when the stacker sensor comes on.
[1] The stacker motor starts running 280 mm (1960 pulses) after the ejection sensor (OFF) ceases to detect paper.
2. Left-Hand Motion
Paper-ejection-wing opening motion
Opening motion ended
Paper-ejection-wing closing motion

Closing motion ended
Ejection sensor Stacker home sensor
Paper detected (ON)
[1] The stacker motor starts running 100 mm (700 pulses) after the ejection sensor detects paper (ON).
No paper detected (OFF)
ON (Position of leftt-hand motion)
OFF (Position of right-hand motion)
Stacker sensor
ON (Stopping position) [2] Error after 1 sec or more Starts running Stopped [2] Error after 1 sec or more Starts running Stopped
Stacker motor
[2] The stacker motor stops running when the stacker sensor comes on.
[1] The stacker motor starts running 280 mm (1960 pulses) after the ejection sensor (OFF) ceases to detect paper.
76 TC (Version 1.0)
Paper-ejection wings closed
Right-hand motion underway
Left-hand motion underway
Explanation of Right-Hand Motion

[Paper-ejection-wing opening motion] [1] [2] Left-hand motion underway The stacker motor starts running after the paper is transported for 100 mm (700 pulses) from the time at which the ejection sensor detects paper (ON). When the stacker sensor comes on (receives light), the stacker motor stops running to end this motion. If the stacker sensor does not come on (does not receive light) within one second after the stacker motor starts running, a stacker-motor lock error is issued, and [E-03] is displayed after the stacker motor is stopped.
[Paper-ejection-wing closing motion] [1] [2] The stacker motor starts after the paper is transported 280 mm (1960 pulses) from the time at which the ejection sensor ceases to detect paper (OFF). When the stacker home sensor comes on (receives light), the stacker motor stops running to end this motion. If the stacker sensor does not come on (does not receive light) within one second after the stacker motor starts running, a stacker-motor lock error is issued, and [E-03] is displayed after the stacker motor is stopped.
Explanation of Left-Hand Motion

[Paper-ejection-wing opening motion] [1] [2] The stacker motor starts running after the paper is transported 100 mm (700 pulses) from the time at which the ejection sensor detects paper (ON). When the stacker sensor comes on (receives light), the stacker motor stops running to end this motion. If the stacker sensor does not come on (does not receive light) within one second after the stacker motor starts running, a stacker-motor lock error is issued, and [E-03] is displayed after the stacker motor is stopped.
[Paper-ejection-wing closing motion] [1] [2] The stacker motor starts running after the paper is transported 280 mm (1960 pulses) from the time at which the ejection sensor ceases to detect paper (OFF). When the stacker home sensor goes off (light is blocked), the stacker motor stops running to end this motion. If the stacker sensor does not go off (light is not blocked) within one second after the stacker motor starts running, a stacker-motor lock error is issued, and [E-03] is displayed after the stacker motor is stopped.
Others
[1] [2] In the swing-stack mode, the machine executes right-hand and left-hand motion alternately, at the timing specified for each stacking motion. The machine performs the paper-ejection-wing opening motion and closing motion on each sheet sequentially, at the specified timing.
77 TC (Version 1.0)
CHAPTER 7. STACKER AREA PAPER-EJECTION-WING INITIALIZING MECHANISM

[3] If a paper jam occurs in the paper-ejection area after a paper-ejection-wing opening motion has been executed, the machine will start the paper-ejection-wing closing motion at that point, thereby preventing the paper-ejection wings from being left open permanently. The sizes indicated in the illustration are counted in encoder pulses (shown in the chart) of the main motor.
[4]
3.
Paper-Ejection-Wing Initializing Mechanism

When the machine is switched on or reset from the test mode, or when ALL RESET is pressed, the machine performs the initializing motion of the paper-ejection wings.
1. Initializing Motion when the Stacker Home Sensor is Receiving Light

Motion started [1] Position of right-hand motion (OFF) [2] Error issued after 1 sec or more Motion ended [3] Non-sensing 50msec range: 50 msec Position of left-hand motion (ON) [2] Error issued after 1 sec or more Position of righthand motion (OFF)
Stacker home sensor
Starts running Stacker motor
Stopped
2. Initializing Motion when Light is Blocked to the Stacker Home Sensor

Motion started [1] Stacker home sensor Motion ended Position of lefthand motion (OFF)
Position of left-hand motion (OFF) [2] Error issued after 1 sec or more
Stacker motor
Starts running
Stopped
[1]
If the stacker home sensor remains OFF (light blocked) before the start of motion, the stacker motor starts running when the stacker home sensor comes on (light received), and runs until the sensor goes off again (light blocked). If the stacker home sensor remains ON (light received) before the start of motion, the stacker motor continues to run until the stacker home sensor goes off (light blocked).
78 TC (Version 1.0)
CHAPTER 7. STACKER AREA PAPER-EJECTON-WING INITIALIZING MECHANISM (LEFT-HAND-ALIGNMENT)

[2] If the state of the stacker home sensor does not change for 1 sec or more while the stacker motor is running, a stacker-motor lock error will be issued, and [E-03] will be displayed after the stacker motor is stopped. The non-sensing range of the stacker home sensor will be provided for 50 msec immediately after the stacker home sensor changes from OFF (light blocked) to ON (light received), in order to prevent improper operation.
[3]
4.
Paper-Ejection-Wing Initializing Mechanism (Left-hand-alignment)

In cases in which the machine has stopped during operation due to a paper jam, or in which the collatedsheet alignment direction differs from the movement direction of the paper-ejection wings at the restart of a collating operation, the machine performs the following motions: 1. If the collated-sheet alignment direction is to the right and the movement direction of the paperejection wings is to the left, at the restart of collation the machine will perform the paper-ejectionwing initializing motion described in the preceding section. If the collated-sheet alignment direction is to the left and the movement direction of the paperejection-wings is to the right, at the restart of collation the machine will perform the paper-ejectionwing initializing motion described below.
2.
Operation start [1]
Motion complete Position of lefthand motion (ON)
Stacker home sensor
Position of right-hand motion (OFF)
[2] Error issued after 1 sec or more Starts running Stacker motor Stopped
Paper-Ejection-Wing Initializing Motion (Left-hand-alignment)

[1] [2] When an operation is initiated, the stacker motor starts running and continues to run until the stacker home sensor comes on (receives light). If the stacker home sensor fails to come on within one second after the stacker motor starts running, a stacker-motor lock error will be issued, and [E-03] will be displayed after the stacker motor is stopped.
79 TC (Version 1.0)
CHAPTER 7. STACKER AREA COLLATED-SHEET FULL-DETECTION MECHANISM
5.
Collated-Sheet Full-Detection Mechanism
300ms
250ms
1000 ms continuously
ON (Light blocked)
Fulldetection sensor
ON (Light blocked)
ON (Light blocked)
Determined to be full [1] [2]
The machine detects the stacked height of collated sheets by means of the full-detection sensor (send) located on the front-side plate, and the full-detection sensor (rcv.) installed on the rear-side plate. When the full-detection sensors stay on for 1000 ms or more continuously, the stacker is determined to be full. At [1], the full-detection sensors come on, but the stacker is not determined to be full, as the sensors do
CHAPTER 7. STACKER AREA REMOVAL OF THE STACKER UNIT

not stay ON for 1000 ms continuously. At [2], the stacker is determined to be full, as the sensors stay ON for 1000 ms continuously.
Disassembly
1. Removal of the Stacker Unit
[1] [2] Remove rear cable cover [A] (two bind-head screws, M3 x 6). Unplug stabilizer connector [B].
C C
A: Rear cable cover B: Stabilizer connector C: Bind-head screws, M3 x 6 2 pcs D: Stacker unit
CHAPTER 7. STACKER AREA REMOVAL OF THE STACKER MOTOR

[3] [4] Remove two screws [C], one each on the right and left of the stacker (two bind-head screws, M3 x 6). Hold stacker unit [D] upright, and push it to the machine main-unit side to remove it.
2.
Removal of the Stacker Motor

[1] [2] [3] Remove the Stacker Unit as described in Section 1. Fully move paper guide (R) [A] to the outer side, loosen set screw [B], and remove motor-shaft gear [C]. Unplug stacker-motor connector [D], remove screws (four pan-head screws SW.W, M3 x 6) [E], and then remove stacker motor [F].
[Precautions on Reassembly] Fasten stacker motor [F] while moving it in the direction indicated by the arrow in the photo.
A E B H
G E
C B
A: Paper guide (R) B: Set screw C: Motor-shaft gear D: Stacker-motor connector E: Pan-head screw SW.W, M3 x 6 4 pcs F: Stacker motor G: Motor shaft H: D-cut face of the motor shaft
CHAPTER 7. STACKER AREA REMOVAL OF THE STACKER SENSOR

Motor-shaft gear [C] should be fastened in parallel with the end face of motor shaft [G]. Align one of two set screws [B] to D-cut face [H] of the motor shaft.
3.
Removal of the Stacker Sensor

[1] [2] [3] Remove the Stacker Unit as described in Section 1. Remove stacker sensor [A] together with stacker-sensor bracket [B] (one pan-head screw SW.W, M3 x 6). Unplug connector [C] from the stacker sensor, and remove the stacker sensor from its bracket [B].
[Precautions on Reassembly] Fasten terminal [D] of the grounding wire to the sensor.
4.
Removal of the Stacker Home Sensor

[1] [2] Remove the Stacker Unit as described in Section 1. Remove stacker home sensor [E] together with stacker-home-sensor bracket [F] (one hex-head RS
D F B
C G
A: Stacker sensor B: Stacker-sensor bracket C: Stacker-sensor connector D: Grounding-wire terminal E: Stacker home sensor F: Stacker-home-sensor bracket G: Stacker-home-sensor connector
CHAPTER 7. STACKER AREA REMOVAL OF THE FULL-DETECTION SENSOR (SEND)

Tight, M3 x 6). [3] Unplug connector [G] from the stacker home sensor, and remove the stacker home sensor from its bracket [F].
5.
Removal of the Full-Detection Sensor (Send)

[1] Remove the covers. Front cover
A: Full-detection sensor (send) B: Full-detection-sensor connector (send)
CHAPTER 7. STACKER AREA REMOVAL OF THE FULL-DETECTION SENSOR (RCV.)

Sensor cover [2] [3] Unplug connector [B]. Remove full-detection sensor (send) [A] (one bind-head screw, M3 x 6).
6.
Removal of the Full-Detection Sensor (Rcv.)

[1] Remove the covers. Rear cable cover Rear cover Unplug connector [B]. Remove full-detection sensor (rcv.) [A] (one bind-head screw, M3 x 6).
[2] [3]
A: Full-detection sensor (rcv.) B: Full-detection-sensor connector (rcv.)
CHAPTER 7. STACKER AREA REMOVAL OF THE FULL-DETECTION SENSOR (RCV.)
CHAPTER 8: VARIOUS SETTINGS
Contents
1. 2. 3. Initialization Settings ........................................................................................................ 8-2 Maintenance Call ............................................................................................................. 8-3 Double-Feed-Detection Cancellation Function .............................................................. 8-4
81 TC (Version 1.0)
CHAPTER 8. VARIOUS SETTINGS INITIALIZATION SETTINGS
1.
Initialization Settings
Initializing Operations
1) 2) 3) Initialization immediately after Power ON Initialize the machine after turning on the power. Initialization to reset from test mode to normal mode Initialize the machine to reset it from the test mode to the normal mode. Initialization using the ALL RESET function Press and hold down the <ALL RESET> key for two seconds with no error displayed; the machine will be initialized.
Statuses after Initialization and Settings

I ni t i al i zat i on I m m edi at el y af t er Pow erO N I ni t i al i zat i on U si ng t he ALL R ESET Funct i on Addi t i on m ode 0 No set t i ng Swi ng st ack O FF O FF D oubl ef eed det ect i on enabl ed f oral l paper f eed bi ns O FF M oved t ol owerl i mi t ( D escendi ng m ot i on) St ar t ed f r om r i ght hand m ot i on Fol l ows set t i ngs i nt he t estm ode I ni t i al i zat i on t o R eset f r om TestM ode t o N or m alM ode Addi t i on m ode 0 No set t i ng Swi ng st ack O FF O FF D oubl ef eed det ect i on enabl ed f oral l paper f eed bi ns O FF M oved t ol owerl i mi t ( D escendi ng m ot i on) St ar t ed f r om r i ght hand m ot i on Fol l ows set t i ngs i nt he t estm ode
St at us Set t i ng
Addi t i on/ Subt r act i on m ode Addi t i on m ode C ounti ndi cat i on Speed St acki ng m ode I nser t i on m ode Sem i act i ve m ode D oubl ef eeddet ect i on set t i ng Joi nt Paper t r ay posi t i on C ol l at edsheetal i gnm ent di r ect i on Tot alcount erm ot i on 0 No set t i ng Swi ng st ack O FF O FF D oubl ef eed det ect i on enabl ed f oral l paper f eed bi ns O FF M oved t ol owerl i mi t ( D escendi ng m ot i on) St ar t ed f r om r i ght hand m ot i on Nor m al
82 TC (Version 1.0)
CHAPTER 8. VARIOUS SETTINGS MAINTENANCE CALL
2.
Maintenance Call
General
The maintenance timing is indicated to the user in accordance with the target maintenance collation count. When the maintenance-collation-count value reaches the target maintenance collation count, Maintenance Call will appear on the display when the machine is switched off and then on again. After the Maintenance Call indication has disappeared, normal collating operation can be conducted. Note, however, that if the maintenance-collation-count value is not cleared, Maintenance Call will again appear on the display the next time the machine is switched on.
Maintenance-Collation-Count Range
From 0 to 999,999 When the count value reaches 999,999, that value will be held.
Setting Method
1. Setting of the target maintenance collation count From 0 to 99 (in units of 10,000) For setting of the target maintenance collation count, refer to Chapter 10, Test Mode. * If this count is set to 0, the Maintenance Call indication will not appear. Checking and clearing of the maintenance-collation-count value For checking and clearing of the maintenance-collation-count value, refer to Chapter 10, Test Mode.
2.
Maintenance-Call Indication
This indication appears only for two seconds after the machine is switched on. LCD indication: [MAINTENANCE E-99]
83 TC (Version 1.0)
CHAPTER 8. VARIOUS SETTINGS DOUBLE-FEED-DETECTION CANCELLATION FUNCTION
3.
Double-Feed-Detection Cancellation Function

General
This function is utilized in remedial action if the double-feed-detection sensor becomes faulty or the paper quality of the sheets being collated is likely to produce improper operations. In such a case, the machine is operated with the double-feed-detection sensors of the paper-feed bins purposely disabled by the user.
Modes
The double-feed-detection cancellation function can be activated in any of the following three modes for each individual bin: 1) No setting Status that is valid immediately after the machine has been switched on. The sensors detect ordinary misfeeds, paper jams, and double feeds. Double-feed-detection cancellation mode 1 Mode in which collation is performed with the detection of misfeeds and paper jams, but not double feeds. Double-feed-detection cancellation mode 2 Mode in which collation is conducted without the detection of misfeeds, paper jams, or double feeds.
2)
3)
Indication Method
Indication in the function selection area The LED of the <FEED CHECK OFF> key indicates whether the double-feed-detection cancellation function is currently active. If the double-feed-detection cancellation function is activated for even one of the bins, the LED will light up. The LED will remain off if that function has not been activated for any of the bins.
LED Status
FEED CHECK OFF
On Double-feed-detection cancellation mode activated Off No setting made
84 TC (Version 1.0)

Indications in the status display area The LED shows the setting status of the double-feed-detection cancellation mode of each bin only while the <FEED CHECK OFF> key is depressed. The LED also indicates the bin in which doublefeeding occurred in the immediately preceding collating operation. Example: Case in which Double-Feed-Detection Cancellation Mode 1 is activated for bin 1, Double-Feed-Detection Cancellation Mode 2 is activated for bin 2, and no setting is made for bins 3 through 10, and also in which double-feeding took place in bin 1 in the immediately preceding collating operation.
Lights up to indicate the bin in which doublefeeding occurred immediately before, but goes out immediately after the power is turned on. The setting status of the double-feed-detection cancellation mode is indicated in this column.
Statuses of Double-Feed-Detection LEDs On Bin with double-feeding Off Bin free of doublefeeding
1 2 3 4 5 6 7 8 9 10
On LED Statuses and Modes Double-Feed-Detection Cancellation Mode 1
Flashing Double-Feed-Detection Cancellation Mode 2 Off No setting made
LCD display Only while the <FEED CHECK OFF> key is depressed, the LCD produces the following indication: [FEED CHCK ON/OFF]
85 TC (Version 1.0)
Setting Method
When the key of the bin number to be set is pressed on the ten-key pad while the <FEED CHECK OFF> key is held down, each press switches the mode as follows: Double-Feed-Detection Cancellation Mode 1 No Setting Double-Feed-Detection Cancellation Mode 1, .... If the key of the bin number to be set on the ten-key pad is held down for one second in No Setting Mode while the <FEED CHECK OFF> key is held down, the mode will change to Double-FeedDetection Cancellation Mode 2. Then, if the key of the bin number to be set is pressed on the ten-key pad while the <FEED CHECK OFF> key is held down, the mode will change to No Setting. If the key of the bin number to be set is held down on the ten-key pad for one second in Double-FeedDetection Cancellation Mode 1 while the <FEED CHECK OFF> key is held down, the mode will change to No Setting immediately after the key is pressed, and will then change to Double-Feed-Detection Cancellation Mode 2. Then, if the key of the bin number to be set is pressed again on the ten-key pad while the <FEED CHECK OFF> key is held down, the mode will change to No Setting. Correspondence between bins and ten-key numbers Bin 1 corresponds to <1> on the ten-key pad, bin 2 to <2>, ... bin 10 to <0>.
86 TC (Version 1.0)

Example of setting operation Example of operation in a case in which Double-Feed-Detection Cancellation Mode 1 is activated for bin 1, Double-Feed-Detection Cancellation Mode 2 is activated for bin 6, and bins 2 through 5 and bins 7 through 10 are in No Setting mode, because bin 1 produced double-feeding in the collating operation immediately prior to the setting of the double-feed-detection cancellation modes. 1) State prior to operation The double-feed-detection cancellation mode is not active in the state prior to the start of operation. The LED of the bin in which double-feeding occurred will come on only while the <FEED
LED Statuses and Modes
1 2 3 4 5 6 7 8 9 10
On
Double-Feed-Detection Cancellation Mode 1
LED Status
FEED CHECK OFF
87 TC (Version 1.0)
CHAPTER 8. VARIOUS SETTINGS PAPER-EJECTION-WING INITIALIZING MECHANISM

CHECK OFF> key is held down. 2) Double-Feed-Detection Cancellation Mode 1 is set for bin 1. Press <1> on the ten-key pad while holding down the <FEED CHECK OFF> key. The <FEED CHECK OFF> key and the LED of bin 1 in the Status Display Area will light up.
1 2 3 4 5 6 7 8 9 10
On
LED Status
FEED CHECK OFF
88 TC (Version 1.0)

* The LED of the bin in which double-feeding occurred in the immediately preceding collating operation lights up only while the <FEED CHECK OFF> key is held down. 3) Double-Feed-Detection Cancellation Mode 2 is set for bin 6. Press <6> on the ten-key pad while holding down the <FEED CHECK OFF> key. The LED of bin 6 in the Status Display Area will flash; setting is now complete.
1 2 3 4 5 6 7 8 9 10
On
LED Status
FEED CHECK OFF
89 TC (Version 1.0)
[Memo]
CHAPTER 9: PANEL DISPLAY
Contents
1. 2. 3. Panel Description ............................................................................................................ 9-2 Summary of Advice Displays ........................................................................................... 9-3 Advice Displays ............................................................................................................... 9-4
91 TC (Version 1.0)
CHAPTER 9. PANEL DISPLAYS PANEL DESCRIPTION
1.
Panel Description
B A
H C
D E
I L J
K M N
A: Paper-tray LEDs 1 to 10 (1 on top, 10 at the bottom) B: Paper-feed-area LEDs 1 to 10 (1 on top, 10 at the bottom) C: Vertical-transport area D: Gate-area LED E: Paper-ejection-area LED F: Paper-ejection-area LED G: Connected-machine-error LED H: Connection-transport-area LED
I: Paper-jam LED J: Double-feed LED K: Misfeed LED L: Full-detection LED M: Setting check LED N: Service-Call LED O: <ALL RESET> key
* Of LEDs [A] to [H], the one corresponding to the position (bin) of the current problem will flash. Of LEDs [I] to [N], one will light up to indicate the type of problem.
92 TC (Version 1.0)
CHAPTER 9. PANEL DISPLAYS SUMMARY OF ADVICE DISPLAYS
2.
Summary of Advice Displays

General Description of Messages
Types of error indications
The machine produces the following five types of error indications: 1. Error messages (E-01E-06, E-99) Vital errors, including maintenance calls Single-error indications Collation-check error indication Errors indicating that the collated sheets may contain a defect Multiple-error indication. The information is indicated by the status LEDs. Multiple-error indication with verification for reset Errors that require verification, such as pressing of the <ALL RESET> key, to be cleared Multiple-error indication. The information is indicated by the status LEDs. Single-error indication with verification for reset Errors that require verification, such as pressing of the <ALL RESET> key, to be cleared Single-error indication Automatic-resetting error indication Errors that clear themselves when the error condition is eliminated Single-error indication
2.
3.
4.
5.
Priority
The priority among the various types of error statuses is as follows unless otherwise specified:
Pr i or i t y ( Hi gher )
Type ofEr r orSt at us 1 Er r orM essage ( EDi spl ay)i ndi cat i on 2 C ol l at i oncheck er r ori ndi cat i on 3 M ul t i pl eer r ori ndi cat i on wi t h ver i f i cat i on f orr eset 4 Si ngl eer r ori ndi cat i on wi t h ver i f i cat i on f orr eset
( Lower )
5 Aut om at i cr eset t i ng er r ori ndi cat i on
93 TC (Version 1.0)
CHAPTER 9. PANEL DISPLAYS ADVICE DISPLAYS
3.
Advice Displays
1) Error Messages (E-Display)
Pr obl em N o. E01
D escr i pt i on ofPr obl em M ai nM ot orLock ( C ALL SER VI C E E01) I fno encodersi gnali s del i ver ed even af t era cer t ai nt i m e per i od has el apsed si nce t he m ai n m ot orbegan r unni ng I fan over cur r entf l ows cont i nuousl yf or0. 8 sec when t he m ai n m ot or st ar t sr unni ng
Cl ear i ng M et hod Pr ess t he <ALL RESET> key .
E02
El evat or M ot orLock ( C ALL SER VI C E E02) I ft he upper l i mi tsensordoes notcom e on even af t erseven seconds has el apsed si nce t he el evat orm ot orbegan r unni ng i nt he ascendi ng di r ect i on I ft he l ower l i mi tsensordoes notcom e on even af t erseven seconds has el apsed si nce t he el evat orm ot orbegan r unni ng i nt he descendi ng di r ect i on I fan over cur r entf l ows cont i nuousl yf or0. 8 sec when t he m ai n m ot or st ar t sr unni ng
Pr ess t he <ALL RESET> key . Tur n of ft he power and t hen t ur ni ton agai n.
E03
St acker M ot orLock ( C ALL SER VI C E E03) I ft he st at uses oft he st ackersensorand st ackerhom e sensordo not change f orm or et han one second f ol l owi ng t he st ar tofoper at i on of t he st ackerm ot or
Pr ess t he <ALL RESET> key . Tur n of ft he power and t hen t ur ni ton agai n. Tur n of ft he power and t hen t ur ni ton agai n. Tur n of ft he power and t hen t ur ni ton agai n. Pr ess t he <ALL RESET> key . Tur n of ft he power and t hen t ur ni ton agai n. Cl eart he countval ue i nt he t estm ode.
E04
C onnect i on I / F com m uni cat i on er r or( C ALL SER VI C E E04) I ft he m achi ne i s oper at ed t hr ough connect i on t o anot herm achi ne and an er r oroccur si n com m uni cat i on wi t ht he M ast erm achi ne orSl ave m achi ne
E05
Post pr ocessi ngm achi ne I / F com m uni cat i on er r or ( C ALL SER VI C E E05) I fa post pr ocessi ng m achi ne i s used and an er r oroccur si n com m uni cat i on wi t ht he post pr ocessi ng m achi ne
E06
St acker ar ea connect i on er r or( C ALL SER VI C E E06) I ft he poweri st ur ned on wi t houtt he st ackerar ea connect ed t ot he connect oroft he m achi ne m ai n uni t
E99
M ai nt enance C al l( M AI N TEN AN C E E99) I ft he m ai nt enancecol l at i oncountval ue i s gr eat ert han t he t ar get m ai nt enance col l at i on count
94 TC (Version 1.0)
2) Collation-check error indications
N o. 1 Er r orf orone set 1
D escr i pt i on ofPr obl em [ 1 SET C H EC K ]appear s. I fan er r oroccur si ndi cat i ng t hatone col l at ed setm ay cont ai n a def ect 2 C heck er r or sf ort w o set s
Cl ear i ng M et hod Pr ess t he <ALL RESET> key . Pr ess t he <ALL RESET> key . Pr ess t he <ALL RESET> key . Pr ess t he <ALL RESET> key .
[ 2 SETS C H EC K ]appear s. I fan er r oroccur si ndi cat i ng t hatt wo col l at ed set s m ay cont ai n a def ect 3 C heck er r or sf ort hr ee set s
[ 3 SETS C H EC K ]appear s. I fan er r oroccur si ndi cat i ng t hatt hr ee col l at ed set s m ay cont ai n a def ect 4 C heck er r or sf orf ourset s
[ 4 SETS C H EC K ]appear s. I fan er r oroccur si ndi cat i ng t hatf ourcol l at ed set s m ay cont ai n a def ect
[Problem indications on the panel] The LEDs on the panel light up. [B]: Lights up if a paper jam occurs in the paper-feed area [C]: Lights up if a paper jam occurs in the vertical-transport area [E]: Lights up if a paper jam occurs in the paper-ejection area [A]: The LED of a bin containing a misfeed flashes. The rest of the LEDs remain off. [F]: Lights up if a problem occurs [I]: Lights up if a paper jam occurs in the paper-feed area, even in a single bin [J]: Lights up if double-feeding occurs, even in a single bin [K]: Lights up if a misfeed occurs, even in a single bin
95 TC (Version 1.0)
3) Other error indications

The multiple-error indications with verification for reset, single-error indications with verification for reset, and automatic-resetting-check error indications are described below.
N o.
D escr i pt i on ofPr obl em Paper j am er r or( M ul t i pl e er r or swi t h ver i f i cat i on f orr eset ) [ PAPER FEED ER R O R ]i s di spl ayed. I fa paperj am occur s [ Pr obl em i ndi cat i ons on t he panel ] The LED s on t he panell i ghtup. [ B] :Li ght s up i fa paperj am occur sint he paper f eed ar ea
Cl ear i ng M et hod Pr ess t he <ALL RESET> key .
[ C] :Li ght s up i fa paperj am occur si nt he ver t i cal t r anspor tar ea [ E] :Li ght s up i fa paperj am occur si nt he paper ej ect i on ar ea [ A] :The LED ofa bi n cont ai ni ng a m i sf eed f l ashes. The r estoft he LED s r em ai n of . [ F] :Li ght s up i fa pr obl em occur s [ I ] :Li ght s up i fa paperj am occur si nt he paper f eed ar ea,even i na i ngl e bi n [ J] :Li ght s up i fdoubl ef eedi ng occur s,even i n a si ngl e bi n [ K] :Li ght s up i fa m i sf eed occur s,even i n a si ngl e bi n Mi sf eed er r or( Si ngl eer r ori ndi cat i on w i t h ver i f i cat i on f orr eset ) [ N O PAPER FEED ]i s di spl ayed. I fa m i sf eed i s pr oduced. [ Pr obl em i ndi cat i ons on t he panel ] The f ol l owi ng LED on t he panell i ght s up. [ A] :The LED oft he cor r espondi ng paper f eed bi nf l ashes,wi t ht he r estr em ai ni ng)of f . O ut of paperer r or( M ul t i pl eer r ori ndi cat i on w i t h ver i f i cat i on f orr eset ) Suppl y paperand pr ess t he <ALL RESET> key . Rem ove t he col l at ed sheet s and pr ess t he <ALL RESET> key. Pr ess t he <ALL RESET> key .
[ AD D PAPER ]i s di spl ayed. I fpaperr uns out Paper f ul ldet ect i on er r or( M ul t i pl eer r ori ndi cat i on w i t h ver i f i cat i on f orr eset ) [ PAPER FU LL]i s di spl ayed. I ft he paper r ecei vi ng t r ay f i l l s up wi t h col l at ed sheet s I ft he f ul l det ect i on sensori s on when a pr obl em i s cl ear ed by pr essi ng t he <ALL RESET > key [ Pr obl em i ndi cat i ons on t he panel ] The f ol l owi ng LED s on t he panell i ghtup. [ F] :The paper r ecei vi ngt r ay LED l i ght s up. [ L] :The f ul l det ect i on LED l i ght s up. *The buzzerwi l lsound i ft he <ALL RESET> key i s pr essed wi t houtt he col l at ed sheet s bei ng r em oved f i r st . Tr anspor t ar ea door open er r or( Aut om at i cr eset t i ng er r ori ndi cat i on) [ C LO SE D O O R ]i s di spl ayed. I ft he t r anspor t ar ea doorr em ai ns open ( The door open swi t ch ( upper ) ,door open swi t ch ( l ower ) ,orm ai nm ot orsaf et y swi t ch i s of f . )
Cl ose t he t r anspor t ar ea door ;t he er r or wi l lbe cl ear ed aut om at i cal l y.
[ Pr obl em i ndi cat i ons on t he panel ] The LED s on t he panell i ghtup. [ C] :The ver t i cal t r anspor t ar ea LED l i ght s up. [ M] :The door cl osur echeck LED l i ght s up. C onnect edm achi ne er r or( Aut om at i cr eset t i ng er r ori ndi cat i on) [ C H EC K JO I N T]i s di spl ayed. I fan er r oroccur si nt he connect ed M ast erm achi ne orSl ave m achi ne [ Pr obl em i ndi cat i on on t he panel ] The f ol l owi ng LED on t he panell i ght s up. [ G] :The connect edm achi neer r orLED l i ght s up. Post pr ocessi ngm achi ne er r or( Aut om at i cr eset t i ng er r ori ndi cat i on) Cl eart he er r ori nt he post pr ocessi ng m achi ne. Cl eart he er r oroft he associ at ed M ast er m achi ne orSl ave m achi ne.
[ C H EC K O PTI O N ]i s di spl ayed. I fan er r oroccur si nt he post pr ocessi ng m achi ne
96 TC (Version 1.0)
CHAPTER 10: TEST MODE
Contents
Test Mode ............................................................................................................................ 10-2 1. 2. 3. 4. 5. 6. Testing Sensor and Switch .................................................................................... 10-3 Testing Motor and Solenoid ................................................................................... 10-4 Sequential Operation Test ..................................................................................... 10-4 Data Display .......................................................................................................... 10-5 Data Clear .............................................................................................................. 10-5 Data Setting ........................................................................................................... 10-6
CHAPTER 10. TEST MODE TEST MODE
Test Mode
1. Activation Method
The Test Mode is activated when the <STOP> key and <X> key are pressed simultaneously for one second with the power turned on.
2.
Operation Method
When the Test Mode is activated, the machine displays the ROM version for two seconds, followed by No. 0. Ex.: ROM Version: Ver. 1.00
TEST MODE Ver. 1.00

Two seconds later
No.
When a test No. is entered via the ten-key pad, the test-mode item name is shown on the display. Pressing the <START> key initiates the test operation. Ex.: Test Mode No. 10: On standby
PAPER SENSOR
Ex.: Test Mode No. 10: TEST/ON
No.
10
TEST/ON PAPER SENSOR 10
No.
10
To cancel the test currently being performed, press the <START> key or <STOP> key. To reset the test No. to 0, press the <C> key while the machine remains on standby.
CHAPTER 10. TEST MODE TESTING SENSOR AND SWITCH
3.
Deactivation Method
The test mode can be deactivated by pressing the <ALL RESET> key for one second while no test operation is under way.
1. Testing Sensor and Switch

The states of the sensors and switches are indicated by a buzzer sound. Detection state: The buzzer sounds at intervals of 0.1 sec. Non-detection state: The buzzer sounds at intervals of 0.5 sec.
N o. 1 | 10 11 | 20 21 22 23 24 25 26 27 28 29 31 32 33 34
Test ed C om ponent P aper det ect i on sensor1 | P aper det ect i on sensor10 P aper f eeddet ect i on sensor1 | P aper f eeddet ect i on sensor10 Ful l det ect i on sensor U pper l i mi tsensor Low er l i mi tsensor P aper ej ect i on sensor D oor open S W ( U pper ) D oor open S W ( Low er ) St ackerhom e sensor St ackersensor Tr anspor tsensor St ackerr ecogni t i on TC m ai nt ow er / S ubt ow err ecogni t i on Joi ntO N r ecogni t i on M ai nm ot orsaf et y SW
D et ect ed S t at e O pt i calaxi s bl ocked ( Pr esence ofbl ocki ng pl at e)
O pt i calaxi s bl ocked ( Pr esence ofpaper ) O pt i calaxi s bl ocked ( Pr esence ofpaper ) O pt i calaxi s bl ocked ( Pr esence ofbl ocki ng pl at e) O pt i calaxi s bl ocked ( Pr esence ofbl ocki ng pl at e) O pt i calaxi s bl ocked ( Pr esence ofpaper ) SW O N SW O N O pt i calaxi s bl ocked ( Pr esence ofbl ocki ng pl at e) Li ghtr ecei ved
St ackeruni tconnect ed TC m ai nt ow er / S ubt ow erconnect ed C onnect i on TC j oi ntuni tconnect ed SW O N
CHAPTER 10. TEST MODE TESTING MOTOR AND SOLENOID
2. Testing Motor and Solenoid

Pressing the <START> key initiates a test, and pressing either the <START> key or <STOP> key cancels the test.
N o. 61 | 70 71 72 73 74 75 76
Test ed C om ponent Paper f eed cl ut ch 1 | Paper f eed cl ut ch 10 M ai n m ot or ,sl ow M ai n m ot or ,f ast St ackerm ot or G at e sol enoi d Joi ntm ot or ,sl ow Joi ntm ot or ,f ast
3. Sequential Operation Test

[1] [2] Pressing the <START> key initiates a unit motion. This test basically checks for the same errors as in ordinary machine operation. The motion will last until a key input is made. If an error occurs, the buzzer will sound continuously. The error can be cleared by pressing the <ALL RESET> key.
N o. 101 C ol l at i ng oper at i on
D escr i pt i on ofTestM ode
The m achi ne per f or mst he nor m alcol l at i ng oper at i on wi t h paperj am det ect i ng f unct i on. *No doubl ef eedi ng det ect ed. Swi ngst ack and col l at i ngspeed changeoverpossi bl e. *The t ot alcount erand m ai nt enance col l at i on countdo notf unct i on. 102 Er r or f r ee col l at i ng oper at i on The m achi ne per f or mst he nor m alcol l at i ng oper at i on wi t houtpaperj am det ect i ng f unct i on. *No doubl ef eedi ng det ect ed. Swi ngst ack and col l at i ngspeed changeoverpossi bl e. *The t ot alcount erand m ai nt enance col l at i on countdo notf unct i on. 103 St ackeroper at i on I ni t i alm ot i on Ri ght hand m ot i on Lef t hand m ot i on af t er0. 5 sec Ri ght hand m ot i on af t er0. 5 sec,r epeat ed t her eaf t er 104 El evat oroper at i on Li f tl everup St opped atupperl i mi t( 0. 5 sec) St opped atl owerl i mi t( 0. 5 sec) St opped at upperl i mi t( 0. 5 sec) ,r epeat ed t her eaf t er
CHAPTER 10. TEST MODE DATA DISPLAY
4. Data Display
Pressing the <START> key displays the data currently set. * The data indications show only the set values and measured values, but those settings cannot be changed here.
N o. 121 | 130
D at a N am e Paper f eeddet ect i on sensor1 A/ D val ue | Paper f eeddet ect i on sensor10 A/ D val ue
D escr i pt i on ofI ndi cat i on The am ountofl i ghti si ndi cat ed as an A/ D val ue. The m ai nm ot orpul se count ,whi ch i st aken f r om when cl ut ch 1 i s engaged unt i lpaper f eeddet ect i on sensor1 com es on,i s di spl ayed f ort wo seconds. | The m ai nm ot orpul se count ,whi ch i st aken f r om when cl ut ch 10 i s engaged unt i lpaper f eeddet ect i on sensor10 com es on,i s di spl ayed f ort wo seconds.
301 | 310
Paper f eed m easur em ent1 | Paper f eed m easur em ent10
5. Data Clear
[1] [2] [3] At Nos. 91 and 93, pressing the <START> key displays the current data. No. 92 is cleared when the <START> key is held down for two seconds and the motion ends. The clearing of data will take effect when the Test Mode is closed following its execution.
N o. N am e 91 M AI NTENANC E C NT Expl anat i on D i spl ays and cl ear st he col l at i on count erval ue f ort he m ai nt enance f unct i on Set t i ng r ange: Setval ue 92 *Pr essi ng t he <C > key f ort wo seconds orm or e cl ear st he count er . Pr essi ng t he <START> key causes a buzzert o sound and com pl et es t he updat e.
C LEAR M EM O RY SW Cl ear st he cont ent s oft he syst em RAM Expl anat i on D at at o be cl ear ed: M em or y SW dat a Setval ue Tar getm ai nt enance M ai nt enance count er Set t i ng r ange:Execut i on onl y *Pr essi ng t he <START> key f ort wo seconds orm or e cl ear st he dat a.
93
C LEAR TTL C O UNTER Expl anat i on C l ear s/ set st he t ot alcol l at i on count Set t i ng r ange:0 999999 Setval ue *Pr essi ng t he <C > key f ort wo seconds orm or e cl ear st he count er . Ent era val ue vi a t he t enkey pad and pr ess t he <START> key . Pr essi ng t he <START> key causes a buzzert o sound and com pl et es t he updat e.
CHAPTER 10. TEST MODE DATA SETTING
6. Data Setting
[1] Pressing the <START> key displays the data currently set and activates a motion. However, at Test Nos. 201 through 210, the machine will initiate an automatic adjustment motion immediately after the <START> key is pressed, and will return to standby upon completion of the adjustment.
N o. 151
N am e Set t i ng oft he t ar getm ai nt enance col l at i on count( SPEC I FY PM C YC LE) Expl anat i on At ar getcol l at i on counti s setf ort he pur pose ofpr oduci ng a M ai nt enance C al l i ndi cat i on. Set t i ng r ange:0 99 ( i n uni t s of10, 000 col l at i ons) Set t i ng uni t :1 ( 10, 000 col l at i ons) Setval ue D ef aul t :0 *I ft hi s counti s sett o 0,t he M ai nt enance C al lf unct i on wi l lbe di sabl ed. The count wi l lbe st ar t ed when a col l at i on counti s ent er ed.
152
Tot alcount erdi sabl ed ( TTL C O UNTER O FF) Expl anat i on The t ot alcount eri s di sabl ed. Set t i ng r ange:Execut i on onl y Setval ue *Thi s set t i ng wi l lt ake ef f ectwhen t he m achi ne i s shutdown and t hen swi t ched on agai n.
201 | 210
Aut om at i cl i ght am ountadj ust m entofpaper f eeddet ect i on sensor1 ( D F SENSO R 1 AUT) | Aut om at i cl i ght am ountadj ust m entofpaper f eeddet ect i on sensor10 The m achi ne f eeds t he col l at i ng paperl oaded i nt he papert r ay t hr ough t ot he sensor posi t i on,and t hen ej ect si tt ot he st ackerar ea af t eraut om at i cal l y adj ust i ng t he am ountofl i ght .I ti ndi cat es t he setval ue oft he aut om at i cal l y adj ust ed am ountofl i ght ort wo seconds,and t hen r et ur ns t o st andby . Expl anat i on f *Thi st estcannotbe per f or m ed i nt he absence ofpaper . Ther ef or e,sever al sheet s oft he col l at i ng paperm ustbe l oaded i nt he papert r ay oft he bi nf or whi ch t he aut om at i c adj ust m enti st o be execut ed. Set t i ng r ange:0 255 Setval ue Set t i ng uni t :1 D ef aul t :50
222 | 230
Paper Feed C l ut ch 2 act i vat i on ( PC LUTC H 1 START) | Paper Feed C l ut ch 10 act i vat i on Expl anat i on Set t i ng oft he act i vat i on t i mi ng ofpaper f eed cl ut ches Set t i ng r ange:10 m m t o +10 m m ( wi t hr espectt ot he basi ct i mi ng) Set t i ng uni t :2 m m D ef aul t :0 m m *Each t i met he <2> key i s pr essed,t he t i mi ng i si ncr eased i n st eps oft he set t i ng uni t ,and each t i met he <8> key i s pr essed,i ti sr educed i n st eps oft he set t i ng uni t .
Setval ue
CHAPTER 10. TEST MODE
N o. 231 | 240
N am e Feed ofPaper Feed C l ut ch 1 ( PC LUTC H 1 RANG E) | Feed ofPaper Feed C l ut ch 10 Expl anat i on Set t i ng oft he am ountoff eedi ng ofpaper f eed cl ut ches Set t i ng r ange:10 m m t o +10 m m ( wi t hr espectt ot he basi c am ountoff eedi ng) Set t i ng uni t :2 m m Setval ue D ef aul t :0 m m *Each t i met he <2> key i s pr essed,t he f eed i si ncr eased i n st eps oft he set t i ng uni t ,and each t i met he <8> key i s pr essed,i ti sr educed i n st eps oft he set t i ng uni t .
241
Set t i ng ofLC D cont r ast( LC D C O NTRAST SET) Expl anat i on Set t i ng ofLC D cont r ast Set t i ng r ange:5t o +5 Set t i ng uni t :1 Setval ue D ef aul t :0 *Each t i met he <2> key i s pr essed,t he cont r asti si ncr eased i n st eps oft he set t i ng uni t ,and each t i met he <8> key i s pr essed,i ti sr educed i n st eps oft he set t i ng uni t .
CHAPTER 11: ELECTRICAL-COMPONENT LIST
Contents
1. 2. 3. 4. Motors ............................................................................................................................ 11-2 Clutches ......................................................................................................................... 11-3 Sensors ......................................................................................................................... 11-4 Switches, and Counter .................................................................................................. 11-7
CHAPTER 11. ELECTRICAL-COMPONENT LIST MOTORS
1.
Motors
A: Main motor B: Elevator motor
CHAPTER 11. ELECTRICAL-COMPONENT LIST CLUTCHES
2.
Clutches
A B C D E F G H I J
Paper-Feed Clutch (Detail)
A: Paper-Feed Clutch 1 B: Paper-Feed Clutch 2 C: Paper-Feed Clutch 3 D: Paper-Feed Clutch 4 E: Paper-Feed Clutch 5
F: Paper-Feed Clutch 6 G: Paper-Feed Clutch 7 H: Paper-Feed Clutch 8 I: Paper-Feed Clutch 9 J: Paper-Feed Clutch 10
CHAPTER 11. ELECTRICAL-COMPONENT LIST SENSORS
3.
Sensors
E F
I J
K L
Paper-Detection Sensor (Detail)
A: Full-Detection Sensor (Send) B: Full-Detection Sensor (Rcv.) C: Upper-Limit Sensor D: Lower-Limit Sensor E: Paper-Detection Sensor 1 F: Paper-Detection Sensor 2 G: Paper-Detection Sensor 3
H: Paper-Detection Sensor 4 I: Paper-Detection Sensor 5 J: Paper-Detection Sensor 6 K: Paper-Detection Sensor 7 L: Paper-Detection Sensor 8 M: Paper-Detection Sensor 9 N: Paper-Detection Sensor 10
A B C D E F G H I J K (d) (c) (b)
(a)
(e)
L
A: Paper-Feed-Detection Sensor (Rcv.) 1 B: Paper-Feed-Detection Sensor (Send) 1 + Paper-FeedDetection Sensor (Rcv.) 2 C: Paper-Feed-Detection Sensor (Send) 2 + Paper-FeedDetection Sensor (Rcv.) 3 D: Paper-Feed-Detection Sensor (Send) 3 + Paper-FeedDetection Sensor (Rcv.) 4 E: Paper-Feed-Detection Sensor (Send) 4 + Paper-FeedDetection Sensor (Rcv.) 5 F: Paper-Feed-Detection Sensor (Send) 5 + Paper-FeedDetection Sensor (Rcv.) 6 G: Paper-Feed-Detection Sensor (Send) 6 + Paper-FeedDetection Sensor (Rcv.) 7 H: Paper-Feed-Detection Sensor (Send) 7 + Paper-FeedDetection Sensor (Rcv.) 8 I: Paper-Feed-Detection Sensor (Send) 8 + PaperFeed-Detection Sensor (Rcv.) 9 J: Paper-Feed-Detection Sensor (Send) 9 + PaperFeed-Detection Sensor (Rcv.) 10 K: Paper-Feed-Detection Sensor (Send) 10 + Paper-Ejection Sensor (Upper) L: Paper-Ejection Sensor (Lower) (a): Paper-Feed-Detection Sensor (Rcv.) 1 (b): Paper-Feed-Detection Sensors (Send) 19 (c): Paper-Feed-Detection Sensors (Rcv.) 210 (d): Paper-Feed-Detection Sensor (Send) 10 (e): Paper-Ejection Sensor (Upper)
CHAPTER 11. ELECTRICAL-COMPONENT LIST SWITCHES, AND COUNTER
4.
Switches, and Counter
A: Door-Open Switch (Upper) B: Door-Open Switch (Lower) C: Power Switch
CHAPTER 11. ELECTRICAL-COMPONENT LIST SWITCHES, AND COUNTER
A: Main-motor safety switch B: Electromagnetic counter
CHAPTER 12: DESCRIPTION OF PCBs
Contents
1. 2. 3. 4. 5. Block Chart ................................................................................................................... 12-2 Location of PCBs .......................................................................................................... 12-3 Main PCB ...................................................................................................................... 12-4 Power-Supply Unit ...................................................................................................... 12-10 Panel PCB .................................................................................................................. 12-12
CHAPTER 12. DESCRIPTION OF PCBs BLOCK CHART
1.
Block Chart
Panel PCB CN1 Paper-feeddetection sensor
CN1
CN2 Paper-feeddetection sensors Total counter
CN3 Various components in the stacker area CN13 IC5 SW2
SW1
Connector for joint operation
CN12
CN4 Paper-Detection Sensors 110
Paper-feed clutches
CN11
IC6
Various components
CN10
Main-motor safety switch
CN9 CN8 CN7 CN6 CN5
Main-motor encoder sensor CN2 CN3
Main motor
Power-supply unit
CHAPTER 12. DESCRIPTION OF PCBs LOCATION OF PCBS
2.
Location of PCBs
A: Main PCB B: Power-supply unit C: Panel PCB
CHAPTER 12. DESCRIPTION OF PCBs MAIN PCB
3.
Main PCB
CN1 CN2
CN3 CN13
CN12
CN4
CN11
CN10
CN9
CN8
CN7
CN6
CN5

CN1
LED & KEY load D-GND LED send data D-DNG LED & KEY clock D-GND D-GND D-GND D-GND D-GND +5 V +5 V +5 V +5 V LCD data 8 LCD data 7 LCD strobe KEY receive data Total KEY D-GND Buzzer D-GND LCD Vo LCD RS LCD WR LCD E LCD data 1 LCD data 2 LCD data 3 LCD data 4 LCD data 5 LCD data 6
32-Pin
Rd Gy Gy Gy Gr Gy Gy Gy Gy Gr Gy Gy Gy Gy Gr Gy Rd Gy Gy Gy Gr Gy Gy Gy Gy Gr Gy Gy Gy Gy Gr Gy
Panel PCB CN1
CN2
+5 V Paper-Feed-Detection Sensor (Rcv.) 1 D-GND Idle Idle +5 V Paper-Feed-Detection Sensor (Rcv.) 2 D-GND +5 V Paper-Feed-Detection Sensor (Rcv.) 1 +5 V Paper-Feed-Detection Sensor (Rcv.) 3 D-GND +5 V Paper-Feed-Detection Sensor (Send) 2 +5 V Paper-Feed-Detection Sensor (Rcv.) 4 D-GND +5 V Paper-Feed-Detection Sensor (Send) 3 +5 V Paper-Feed-Detection Sensor (Rcv.) 5 D-GND +5 V Paper-Feed-Detection Sensor (Send) 4 +5 V Paper-Feed-Detection Sensor (Rcv.) 6 D-GND +5 V Paper-Feed-Detection Sensor (Send) 5
30-Pin
Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Br Rd Or
Paper-Feed-Detection Sensor (Rcv.) 1
Br Rd Or Yw Gr Br Rd Or Yw Gr Br Rd Or Yw Gr Br Rd Or Yw Gr Br Rd Or Yw Gr
Paper-Feed-Detection Sensor (Rcv.) 2 Paper-Feed-Detection Sensor (Send) 1 Paper-Feed-Detection Sensor (Rcv.) 3 Paper-Feed-Detection Sensor (Send) 2 Paper-Feed-Detection Sensor (Rcv.) 4 Paper-Feed-Detection Sensor (Send) 3 Paper-Feed-Detection Sensor (Rcv.) 5 Paper-Feed-Detection Sensor (Send) 4 Paper-Feed-Detection Sensor (Rcv.) 6 Paper-Feed-Detection Sensor (Send) 5
CN3
+5 V Paper-Feed-Detection Sensor (Rcv.) 7 D-GND +5 V Paper-Feed-Detection Sensor (Send) 6 +5 V Paper-Feed-Detection Sensor (Rcv.) 8 D-GND +5 V Paper-Feed-Detection Sensor (Send) 7 Idle +5 V Paper-ejection sensor D-GND +5 V Paper-Feed-Detection Sensor (Rcv.) 9 D-GND +5 V Paper-Feed-Detection Sensor (Send) 8 +5 V Paper-Feed-Detection Sensor (Rcv.) 10 D-GND +5 V Paper-Feed-Detection Sensor (Send) 9 +5 V Paper-Feed-Detection Sensor (Send) 10 +24 V-A Total counter
28-Pin
Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Br Rd Or Yw Gr Br Rd Or Yw Gr
Paper-Feed-Detection Sensor (Rcv.) 7 Paper-Feed-Detection Sensor (Send) 6 Paper-Feed-Detection Sensor (Rcv.) 8 Paper-Feed-Detection Sensor (Send) 7
Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh
Br Rd Or Yw Gr Br Rd Or Yw Gr Br Rd Or Yw Gr
Paper-Feed-Detection Sensor (Rcv.) 9 Paper-Feed-Detection Sensor (Send) 8 Paper-Feed-Detection Sensor (Rcv.) 10 Paper-Feed-Detection Sensor (Send) 9 Paper-Ejection Sensor (Rcv.) Paper-Feed-Detection Sensor (Send) 10 Total counter
CN4
+24 V_A Paper-feed clutch, bin 1 +24 V_A Paper-feed clutch, bin 2 +24 V_A Paper-feed clutch, bin 3 +24 V_A Paper-feed clutch, bin 4 +24 V_A Paper-feed clutch, bin 5 +24 V_A Paper-feed clutch, bin 6 +24 V_A Paper-feed clutch, bin 7 +24 V_A Paper-feed clutch, bin 8 +24 V_A Paper-feed clutch, bin 9 +24 V_A Paper-feed clutch, bin 10
20-Pin
Br Rd Br Rd Br Rd Wh Bk Wh Bk Wh Bk Wh Bk Wh Bk Wh Bk Wh Bk
Paper-feed clutch, bin 1 Paper-feed clutch, bin 2 Paper-feed clutch, bin 3 Paper-feed clutch, bin 4 Paper-feed clutch, bin 5 Paper-feed clutch, bin 6 Paper-feed clutch, bin 7 Paper-feed clutch, bin 8 Paper-feed clutch, bin 9 Paper-feed clutch, bin 10
CN5
+24 V-C P-GND
2-Pin
Wh Wh Power-supply unit CN3
CN6
+5 V D-GND A+6 V A-GND P.F. A.F. +24 V-A P-GND +24 V-B P-GND
10-Pin
Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh
Power-supply unit CN2
CN7
Main motor Main motor + FG
3-Pin
Wh Rd Bk Bl Rd Bk
Main motor
CN8
+5 V Main-motor encoder sensorv D-GND
3-Pin
Br Rd Or Rd Wh Bk Main-motor encoder sensor
CN9
2-Pin
+24 V-A SAFE Vo
Yw Yw
Main-motor safety switch

CN10
Door-open (upper) SW D-GND Door-open (lower) SW D-GND LED D-GND +5 V +24 V-A Drive Idle Idle Idle +5 V D-GND Idle Idle Idle Idle +5 V Upper-limit sensor D-GND +5 V Lower-limit sensor D-GND +5 V LED D-GND Full-detection sensor Elevator motor 1 Elevator motor 2 Idle Idle Idle Idle
34-Pin
Br Rd Or Yw Gr Bl Vt Gy Wh Br Rd Or Yw Gr Bl Vt Gy Wh Door-open (upper) SW Door-open (lower) SW Full-detection sensor Gate solenoid (OP)
Or Yw
Or Yw
Gr Yw
Paper-Ejection Sensor (Send)
Wh Br Br Rd Or Yw Gr Bl Vt Gy Wh Br
Upper-Limit Sensor
Lower-Limit Sensor
Full-Det. Sensor (Rcv.)
Br Rd
Elevator motor
CN11
Paper-detection sensor, bin 1 D-GND Paper-detection sensor, bin 2 D-GND Paper-detection sensor, bin 3 D-GND Paper-detection sensor, bin 4 D-GND Paper-detection sensor, bin 5 D-GND Idle Paper-detection sensor, bin 6 D-GND Paper-detection sensor, bin 7 D-GND Paper-detection sensor, bin 8 D-GND Paper-detection sensor, bin 9 D-GND Paper-detection sensor, bin 10 D-GND Idle
22-Pin
Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Vt Paper-detection sensor, bin 1 Paper-detection sensor, bin 2 Paper-detection sensor, bin 3 Paper-detection sensor, bin 4 Paper-detection sensor, bin 5
Paper-detection sensor, bin 6 Paper-detection sensor, bin 7 Paper-detection sensor, bin 8 Paper-detection sensor, bin 9 Paper-detection sensor, bin 10
CN12 16-Pin
Idle +5 V RxD Transport IN sensor TxD D-GND CTS +5 V RTS Transport IN sensor D-GND D-GND M/S Activation signal D-GND D-GND Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh
Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh
Joint
CN13
Idle Activation signal TxD +5 V RxD Transport-motor PWM RTS Transport-motor enable CTS Transport-motor overcurrent D-GND D-GND +5 V +5 V Stacker sensor Transport-motor encoder sensor D-GND D-GND +5 V Paper-ejection device 1 Stacker home sensor Paper-ejection device 0 D-GND D-GND Stacker motor 1 Stacker motor 2 +24 V-B +24 V-B P-GND P-GND
30-Pin
Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Wh Bk Bk Bk Bk Bk Bk
Br Rd Or
Stacker sensor
Yw Gr Bl
Stacker home sensor
Vt Gy
Rd Bk
Stacker motor
CHAPTER 12. DESCRIPTION OF PCBs POWER-SUPPLY UNIT
4.
Power-Supply Unit
CN4
CN3
CN2
F4 F3 F2
F60
F1
CN1
CHAPTER 12. DESCRIPTION OF PCBs POWER-SUPPLY UNIT
Correspondence Table of Fuses for the Power-Supply Unit

C onnect ed C om ponent / Appl i cat i on
Fuse N o.
Fuse R at i ng
Syst em
F1
4 A/ 250 V
AC i nput
Pr ot ect i on f orAC i nput
F2
3. 15 A/ 250 V
+24 VA
El evat orm ot or St ackerm ot or Paper f eed cl ut ch
F3
3. 15 A/ 250 V
+24 VB
O pt i on
F4
6. 3 V/ 250 V
+24 VC
M ai n m ot or
F60
3. 15 A/ 250 V
+5 V
Logi c
CHAPTER 12. DESCRIPTION OF PCBs PANEL PCB
5.
Panel PCB
CN1

TC5100

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CONTENTS

CHAPTER 2: MACHINE SUMMARY

CHAPTER 3: MAIN-UNIT DRIVE AREA

CHAPTER 4: PAPER-FEED AREA

Removal of the Transport Roller ................................................................................................... 4-15

10. Removal of the Drive Belt .............................................................................................................. 4-16

CHAPTER 5: VERTICAL-TRANSPORT AREA

CHAPTER 6: PAPER-EJECTION AREA

CHAPTER 7: STACKER AREA

CHAPTER 8: VARIOUS SETTINGS

CHAPTER 9: PANEL DISPLAY

CHAPTER 10: TEST MODE

CHAPTER 11: ELECTRICAL-COMPONENT LIST

CHAPTER 12: DESCRIPTION OF PCBs

CHAPTER 13: TIMING CHARTS

10. Detailed Operation of Collation 2 ................................................................................................ 13-25

CHAPTER 1. MAINTENANCE PREFACE

2. Always connect electrical connectors firmly.

Wire harness connector

Press the ends.

Press the center, firmly.

CHAPTER 1. MAINTENANCE WORK PRECAUTIONS

Assembly and Installation

20 W30 W Flat, round

CHAPTER 1. MAINTENANCE WORK PRECAUTIONS

Electrical system work

they can be easily damaged.

Light receiving unit

Light receiving unit

Light emitting unit Light emitting unit

Light receiving unit

Light receiving unit

N.C. N.O. Common terminal Common terminal

CHAPTER 1. MAINTENANCE INSTALLATION

RISO Collator TC5100 Installation Procedure

= With the dedicated stand =

Stand support B Stand support A bracket Stand support B bracket

hand facing the front opening of the stand.

Stand support A bracket

Stand support A This document is printed on recycled paper.

CHAPTER 1. MAINTENANCE INSTALLATION

Turn the stand on its feet.

Washered screw M6x10, 4 pcs

CHAPTER 1. MAINTENANCE INSTALLATION

= Without the dedicated stand =

TC base support B (with Binding screws M4x6 2 pcs. each)

TC base support C (with Double-washered screws M4x8 3 pcs.)

= Setting up the TC5100 =

Paper receiving unit support F

Paper receiving unit

CHAPTER 1. MAINTENANCE INSTALLATION

Rear cable cover

Set the Paper feed trays orderly from bottom to top.

CHAPTER 1. MAINTENANCE EXTERIOR COVER REMOVAL

Exterior Cover Removal

(Bind-head Screw, M4 x 8 7 pcs)

B: Sensor cover (Bind-head Screw, M4 x 8 4 pcs)

CHAPTER 1. MAINTENANCE EXTERIOR COVER REMOVAL

(Bind-head Screw, M4 x 8 11 pcs)

D: Rear cable cover (Bind-head Screw, M3 x 8 2 pcs)

CHAPTER 1. MAINTENANCE EXTERIOR COVER REMOVAL

E: Stabilizer F: Motor cover

(Bind-head Screw, M4 x 8 4 pcs) (Bind-head Screw, M3 x 8 4 pcs)